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CONTINUOUS FLOW ICEMAKER

1. Di e i 5 E ss Sn SAF BE N o Ow a CE GE e Po rS 2 B ES e ap se gt 5 SES z TE E Al Cad 15 eat o BI 7 U dau a YOLOVdVO E NOM s z JOSSIYANOD JOLOVAVI Wm d ie dau i m 033 a Ll ac ASSI a RB YOLOVINOD ac i Bi Ba E NIVIN Na 5 34 2 2 2 Nad THU D 1437 MOION YV39 LL JOLON Avi Si WHT RED 8 np Hos ex LA 1 q wR a Una E H E TOMLNOD TNT 81M Eh 13 TOMLNOD WI HIM ac m 1H9IN TOMINOO M a8 L131 1031NOO NIB IHM 18 4 i m zu M SE a m Iz c CH Vo 1d 033 Wo ES os o N Figure 11 Schematic and Wiring Diagram WCC2001 R and WCF2201 R 2002 2014 Cornelius Inc 12 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual C gt GUIDE TO SERVICE ICEMAKER CLEANING AND SANITIZING PROCEDURES Do not use any of the ice made during cleaning operations Clean and sanitize ice storage area when cleaning icemaker 1 Turn off Machine 2 Shutoff water supply 3 Remove ice from storage bin 4 Mix approved cleaner 2 gallons as directed Recommended cleaner Calgon Corp of Virginia Chemicals ice machine cleaner Mixture 3 1 3 ounces per gallon of water 5 Clean auger diverter assembly and ice transition drop tube in a sink usi
2. E I J el el z S a a START CAP RUN CAP Ee Up ee H START RELAY Lt 7 FAN MOTOR Figure 7 Schematic and Wiring Diagram for WC500 A WCC 500 W WCC700 A WCC700 W WCF510 A WCF510 W WCF710 A and WCF710 W ie ehe WHITE BLACK c COMPRESSOR s J e BN ONTRO s rw SWITCH L Si VW LOW wmm IH d C QM d oi gem m y d 9e waer L n COOLED 208 230 gt ON HIGH RES j 80 HZ CUTOUT I won d die SERVICE amp SWITCH AUGER z AUX BIN GEAR CONTROL MOTOR L adi es I pec Le IN FAN ale MOTOR e vv v Figure 8 Schematic and Wiring Diagram for WCC701 A WCC701 W WCF1001 A WCF1001 W WCF711 A WCF711 W WCF1101 A and WCF1101 W 2002 2014 Cornelius Inc 10 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual 2 BLK i e lt RES e u o cie r
3. CHECK ICE MAKER Use gauges for checking suction and head pressures See manual for correct reading and conditions Check frost line and sight glass Check water level for proper adjustment and restrictions See Manual Check evaporator assembly for worn parts bearings scored evaporator and auger bad expansion valve etc Check for loose parts and screws rattling Check evaporator assembly for worn parts bearings scored evaporator and auger bad expansion valve etc 2002 2014 Cornelius Inc eys 6unooysejgnoj ez aunbig eqni JojejodeAe ul UMOP SI peau Guipnujxe 1 yo uo xoqie 6 ul seo goe Jozjowseab UO SAP Y22949 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual 226 NEA uorsuedxe eNjoejep JO pue uoneinsu 10 uomeo
4. 2 2 46 R404A 25 N NOTE For units not listed in above chart refer to nameplate or contact factory service Publication Number 638085278 3 2002 2014 Cornelius Inc C ine gt Continuous Flow Icemaker Installation and Service Manual WCC500 400 380 360 340 320 1 300 L 280 260 E 240 9 g 70 6 50 Water Temperature Deg F 50 70 90 100 Air Temperature Deg F 14 50 24 50 FRONT Capacity Lbs 24 hr WCC700 WCC1000 650 1100 600 1000 550 x 90 WA s 80 gt eg pem MN E D 40 9 pr A 600 350 90 80 70 60 50 90 80 70 60 50 Water Temperature Deg F Water Temperature Deg F 50 70 90 100 50 70 90 100 Air Temperature Deg F Air Temperature Deg F Temperature Charts re 25 00 1 38 cal D INLET 3 8 FLARED WATER COOLED ONLY OUTLET 3 8 FLRE Le WATER COOLED ONLY DRAIN 3 8 ID TYGON TUBE 10 15 WATER IN 1 4 FLARE ELECTRIC 7 8 DIA 1 50 a 1 81 2 12 SIDE ES 2 50 a 1 19 BACK VIEW AIR OR WATER COOLED L FRONT BIN CONTROL PROBE B ICE DISCHARGE 2 06 L 14 21 BOTTOM VIEW VIEWED FROM BOTTOM OF MACHINE Figure 1 Series 500 amp 700 Dimension Drawing Shipping Wt Approx 160 Ibs 2002 2014 Cornelius Inc Publication N
5. 638085278 Continuous Flow Icemaker Installation and Service Manual INSTALLATION This section covers unpacking and inspection selecting location installing unit preparing for operation and operation A REMOVE ICEMAKER FROM CARTON 1 Keep unit in the upright position remove carton and pallet from unit and inspect unit for damage Upon inspection of unit if any damage is found file a claim with carrier immediately 2 Locate startup card either on outside of container or on plastic liner Fill in proper information and send one copy to factory and other copy to distributor Postage is prepaid CABINET REMOVAL Front Panel Remove 4 screws and pull forward Top Panel Remove screws and lift upward 4 screws 500 700 6 screws 1000 Side Panel Remove 4 screws and pull forward 9 M pg Back Panel Should not be removed C PREPARATION OF INSTALLATION SITE The refrigeration system on air cooled units requires airflow so a well ventilated area should be chosen A min imum of 6 inches must be maintained free of any obstructions for air intake A minimum of 4 inches clearance is required for air exhaust 2 The unit can be installed either on an ice storage bin or ice dispenser using the proper adapter kits Refer to sales literature for information The install is kit provided with each icemaker and adapter kits will supply every thing to locate unit correctly In all cases the icemaker should be sealed al
6. W C 1 638036168 638036168 638036168 Bin Probe Holder WCC 1 638036079 638036079 638036079 Bin Probe Holder WCF 1 13 638009387 638009387 638009387 Switch Bin Control 1 638007341 03 638007341 03 638007341 03 Strain Relief 1 638007352 01 638007352 01 638007352 01 Bushing 1 NOTE Not Shown Publication Number 638085278 39 2002 2014 Cornelius Inc Continuous Flow Icemaker Installation and Service Manual Figure 34 Electrical Assembly Model 1000 and 2000 Series Item Item Part No Name No 6 638010002 Relay 7 638004791 Switch Toggle 8 638036067 Switch Assembly Bin Control WCC Switch Assembly Bin Control WCF 9 638004037 Cable Clip 10 163800734103 Strain Relief 11 1638036038 Bracket Run Capacitor WCC1000 12 1638009757 Cap Capacitor WCC1000 13 1638009347 Bracket Start Capacitor WCC1000 11 amp 13 630200166 Capacitor Strap WCC2000 14 638004792 Indicator Plate Toggle Switch 15 1638007214 Nut Hex 15 32 16 1638007215 Nut Face 15 32 17 163800730304 Washer Lock 15 32 Internal Tooth 18 638009387 Switch Bin Control Part No Name No 638090322 Start Relay 208 230 60 Hz WCC1001 and WCF1101 638090242 Start Relay 220V 50 Hz WCC1002 and i WCF1102 40285 Start Relay 208 230 60 Hz WCC2001 and WCF2201 1619980
7. 115V 2 638090241 Compressor 208 230V 638090231 Compressor 220V 50Hz 638036295 01 Electrical Box Assembly WCC700 A 638036295 02 Electrical Box Assembly WCC701 A WCC702 A 638036295 03 Electrical Box Assembly WCC700 W 3 638036295 04 Electrical Box Assembly WCC701 W 638036295 06 Electrical Box Assembly WCF710 A 638036295 07 Electrical Box Assembly WCF711 A WCF712 A 638036295 08 Electrical Box Assembly WCF710 W 638036295 09 Electrical Box Assembly WCF711 W 4 638036273 Condenser Air Cool 638036272 Condenser Water Cool 638004643 05 Water Level Control Assembly 638090226 Expansion Valve Thermal 638090236 Fan Motor Assembly 115V 7 638090234 Fan Motor Assembly 208 230V 638090233 Fan Motor Assembly 220V 50 Hz 8 638096723 Fan Blade 9 1638008814 Bracket Fan Motor 10 1638008812 Panel Center 11 638036218 Bracket Mounting Icemaker 12 1638008409 Bulkhead Fitting 13 638007206 04 Nut Jam 1 2 20 14 1638004393 Dryer 638036865 Cover and Detector Assembly Dispense Tray 15 l638036883 Cover Dispense Tray 638036867 001 Clip Cover 2002 2014 Cornelius Inc 32 NOTE Not Shown Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Gua Left Side View Figure 28 Refrigeration and Icemaker Assembly Model 1000 Series Publication Number 638085278 33 2002 2014 Cornelius Inc Continuous Flow Icemaker Installation and Service Manual REFRIGERATION
8. 2002 2014 Cornelius Inc 29 Publication Number 638085278 REFRIGERATION AND ICEMAKER ASSEMBLY MopEL 500 SERIES um Part No Description 638090130 Front End Assembly WCC500 638090130 002 Front End Assembly WCC502 638090143 Front End Assembly WCC510 638090143 002 Front End Assembly WCC512 e 638090121 Compressor 115V 638090131 Compressor 240V 50Hz 638036295 01 Electrical Box Assembly WCC500 A 638036295 03 Electrical Box Assembly WCC500 W 638036295 05 Electrical Box Assembly WCC502 A 3 638036295 06 Electrical Box Assembly WCF510 A 638036295 08 Electrical Box Assembly WCF510 W 638036295 10 Electrical Box Assembly WCF512 A 4 638008854 Condenser Air Cool 638036383 Condenser Water Cool 638004643 05 Water Level Control Assembly 638090126 Expansion Valve gt 638036225 x Fan Motor Assembly 115V 638010017 Fan Motor Assembly 240V 50Hz 8 638008618 Fan Blade 9 638008814 Bracket Fan Motor 10 638008812 Panel Center 11 638036218 Bracket Mounting Icemaker 12 638008409 Bulkhead Fitting 13 638007206 04 Nut Jam 1 2 20 14 1638004393 Dryer 2002 2014 Cornelius Inc 30 Continuous Flow Icemaker Installation and Service Manual Hi Part No Description 638036865 Cvr amp Detector Assembly Dispense Tray 15 638036883 Cover Dis
9. Flow Icemaker Installation and Service Manual PARTS LIST 10 Figure 24 Refrigeration and Icemaker Assembly Model 2000 Series Exploded View and Parts List Item No Part No Description i 162964027 Compressor WCC2001 and WCF2201 162964046 Compressor WCC2002 and WCF2202 638036849 Condenser WCC and WCF Air 2 27177 Condenser WCC and WCF Water 161870007 Condenser WCC and WCF Remote 638090344001 Fan Motor WCC and WCF Air 50 and 60 HZ 27185 Fan Motor Remote 50 and 60 HZ 63809034401 Fan Blade Air 630900246 Fan Blade WCC and WCF Remote 5 638004391 Bracket Fan Motor 6 638036087 Clamp Dispense Tray 7 638036872001 Dispense Tray Assembly 8 638036882 Cover Dispense Tray 9 638036884 Detector Assembly Ice level 10 638036867001 Clip Cove 11 638036020001 Drop Tube Assembly 12 638092537 Cover Electrical Box 18 164980002 Water Regulator Valve Water Not Shown 14 638009755 High Pressure Switch Water Not Shown 15 161773003 Pressure Switch WCC and WCF Remote Not Shown 16 166226000 Valve Head Pressure WCC and WCF Remote Not Shown 17 166225000 Receiver WCC and WCF Remote Not Shown O 2002 2014 Cornelius Inc 28 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Right Side View 15 Figure 25 Refrigeration and Icemaker Assembly Model 500 Series O
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11. gt D ro ANTI FREEZE e 9 ae RELAY e x ee z z mc NE o ore se Bale gee apol is SE El E lt MAIN pe su a 7 u CONTACTOR EX pe zo lt c 208 230 CRANK T m 5 u 1 RI VAC CASE x EM BIS EE Se IR HEATER e 20 eI teque ex 7 1E3753 SEER no 0 e o C EZ MCC1001R 285 a 3 x an z u z Ce RED 9 aa COMPRESSOR e e MCC701R Figure 9 Schematic and Wiring Diagram WCF1101R WCC1001R WCF1102R amp WCC1102R Brown i t c s p gt Compressor a Le Fen at CONTROL e KE de v el cr al LOW WATER SAFETY jx sasi SWITCH L WATER A r JE COOLED y r kl 220 240 dii ONLY We pees M 50 HZ e SWITCH di 3 SERVICE 5 SWITCH TAX n a 8 BIN CONTROL oy L SWITCH le START H d RELAY perla LA ME e A B le Yel Fan Motor Blue Figure 10 Schematic and Wiring Diagram WCC502 WCC702 WCC1002 WCF512 WCF712 amp WCF1102 Publication Number 638085278 11 2002 2014 Cornelius Inc Cea Continuous Flow Icemaker Installation and Service Manual
12. the icemaker and hermetic refrigeration system is necessary before any adjustments are made The refrigeration technician must use high and low side pressure readings water and air temperatures plus general conditions of cleanliness to assess the refrigeration system status when making any adjustments All icemaker products are tested and adjusted at the factory prior to shipment where the ambient temperature ranges from 65 to 90 F depending on the season of the year Whenever a new icemaker product is initially installed and started up it is imperative that the start up operation make the following checks and or readjustments for local conditions EXPANSION VALVE You will find a thermostatic expansion valve on icemakers which is used to control the amount of refrigerant flowing through the evaporator Improperly installed or defective expansion valves may cause low production soft ice squeaking from evaporator and excessive load inside evaporator By using general refrigeration system troubleshooting along with the pressure charts you can easily determine whether or not the expansion valve is working properly ADJUSTMENT AND TROUBLESHOOTING When troubleshooting the expansion valve you must first be sure you have adequate water flowing into evaporator a clean condenser unit is properly ventilated and system is properly charged and free from any restrictions Also be sure compressor is operating properly Second take reservoir wat
13. 0 500 Rin i Sr z e 4 638036069 Reed Switch Assembly WCC1000 ing Nu 638092531 Reed Switch Assembly WCC2000 638090348 Reservoir WCC1000 2000 638004717 Bracket Water Level 638090346 Reservoir Outlet WCC1000 2000 5 638090347 Bracket Water Level WCC1000 638047005 Gasket WCC1000 2000 638092529 Bracket Water Level WCC2000 638007217 Nut 1 14 WCC1000 2000 638008097 Clamp Reed Switch 638030823 Hardware Water Level Control 638007002 01 Screw Valve Body Cotter Pin Cap j Spacer Plunger Rubber Washer Fiber Nut Sleeve Nut Compression 2002 2014 Cornelius Inc Gea Continuous Flow Icemaker Installation and Service Manual Figure 30 Front End Assembly Model 500 Series Exploded View and Parts List Item Part No Description SC Part No Description No d 5 638090053 E Ring 638090130 Front End Assembly WCC500 6 638007302 06 Washer Lock 1 4 Split 638090130 002 Front End Assembly WCC502 7 638007088 06 Screw 1 4 20 x 3 4 Lg HHMS 638090143 Front End Assembly WCF510 8 638036373 001 Evaporator Assembly 638090143 002 Front End Assembly WCF512 z 9 638090113 Auger 1 1638090001 002 Gearmotor Less Cable Seals O ring seal mount 220V 50 Hz 10 638090117 Extruding Head WCC 638090050 002 Gearmotor 115V with Service Kit 11 638090118 Extruding Head WCF 638090050 005 Gearmotor Complete 115V 220V 50Hz 12 638090126 Expans
14. 02 W Water Cooled 220 240 50 8 2 N A 1 6 13 R404A 20 WCF710 A Air Cooled 115 60 12 1 6 2 24 R404A 20 WCF710 W Water Cooled 115 60 12 N A 2 13 R404A 20 WCC711 A Air Cooled 208 230 60 7 7 1 6 2 24 R404A 20 WCC711 W Water Cooled 208 230 60 7 7 N A 2 13 R404A 20 WCF712 A Air Cooled 220 240 50 8 2 0 5 1 6 24 R404A 20 WCF712 W Water Cooled 220 240 50 8 2 N A 1 6 13 R404A 20 WCC1001 A Air Cooled 208 230 60 7 5 0 85 2 26 R404A 20 WCC1001 W Water Cooled 208 230 60 7 5 N A 2 17 R404A 20 WCC1002 A Air Cooled 220 240 50 8 9 0 85 2 26 R404A 20 WCC1101 A Air Cooled 208 230 60 7 5 0 85 2 26 R404A 20 WCC1101 W Water Cooled 208 230 60 7 5 N A 2 17 R404A 20 WCF1102 A Air Cooled 220 240 50 8 9 0 85 2 26 R404A 20 WCC1001 R Remote 220 240 60 7 5 N A 2 120 R404A 15 WCF1101 R Remote 208 230 60 7 5 N A 2 120 R404A 15 WCC2001 A Air Cooled 208 230 60 12 9 0 85 2 2 46 R404A 25 WCC2001 R Remote 220 240 60 12 9 1 7 2 2 220 R404A 25 WCC2001 W Water Cooled 208 230 60 12 9 N A 2 2 28 R404A 25 WCC2002 A Air Cooled 220 240 50 11 4 0 85 2 2 46 R404A 25 WCF2201 A Air Cooled 208 230 60 12 9 0 85 2 2 46 R404A 25 N N PY N N N N IO N N N N N N N N N N M i IO IO M i TO IO IO PY N N N IO IO N N N WCF2201 W Water Cooled 208 230 60 12 9 N A 2 2 28 R404A 25 Al Aa sch m dl m m m sch m sy m m m sch m m m a sch sch od sch dl sch sch WCF2202 A Air Cooled 220 240 50 114 0 85
15. 0227 Front End Assembly WCF710 638090227 001 Front End Assembly WCF71 1 638090227 002 Front End Assembly WCF712 d i Part No Description 16 638036213 x Drop Tube Assembly 17 638036269 Clamp Dispense Tray 18 638036869 001 Dispense Tray Assembly 19 1638031762 Gasket Foam 3 4 x 3 4 x 13 Lg 20 1638007383 Access Port 21 638007385 Replacement Cap 22 638036884 Detector Assembly Ice Level 23 638007208 03 Nut Palnut 3 4 16 24 638008834 Bracket Mounting Condenser 25 638009755 Pressure Switch 26 638090021 Water Regulating Valve 27 638036188 Receiver Upright 28 638036194 Valve Head Pressure 29 638037110 Washer Seal 30 638037111 Valve Rotolock 31 638037128 01 Crankcase Heater Assembly 638090232 Electrical Box Assembly Compressor WCC700 115V WCF710 32 638090232 001 Electrical Box Assembly Compressor WCC701 208 230V 60 Hz WCF711 638090232 002 Electrical Box Assembly Compressor WCC702 220V 50 Hz WCF712 33 638090235 Condenser Shroud 34 638090222 Relay Start 115V 35 638090242 Relay Start 208 230V 60 Hz 36 638090238 Relay Start 220V 50Hz 37 638090223 Capacitor Run 115V 38 638090243 Capacitor Run 208 230V 60 Hz 39 638090224 Capacitor Start 115V des 638090244 Capacitor Start 208 230V 60Hz Capacitor Start 220V 50Hz 638090221 Compressor
16. 13 Start Relay 220 50 Hz WCC2002 and WCF2202 638090054 Contactor 208 230 50 60 Hz 63800726605 Nut Tinnerman 638090323 Capacitor Run 208 230 V 60 Hz WCC1001 and WCF1101 638090333 Capacitor Run 220 V 50 Hz WCC1002 and WCF1102 161192005 Capacitor Run 208 230 V 60 Hz WCC2001 and WCF2201 161192005 Capacitor Run 220 V 50 Hz WCC2002 and WCF2202 638090324 Capacitor Start 208 230 V 60 Hz WCC1001 and WCF1101 638090244 Capacitor Start 220V 50 Hz WCC1002 5 and WCF1102 41044 Capacitor Start 208 230 V 60 Hz WCC2001 and WCF2201 161165013 Capacitor Start 220 V 50 Hz WCC2002 and WCF2202 2002 2014 Cornelius Inc 40 NOTE Not Shown Publication Number 638085278 Cornelius Inc www cornelius com
17. 638090001 Gearmotor 115V Without Service Kit 16 1638090220 Bearing Delrin 638090001 002 Gearmotor 220V 50 Hz Without Service Kit 638090001 001 Gearmotor 208 23 V 60Hz 2 638090215 Shaft Seal Mount 3 638090051 Shaft Seal 4 638007301 030 Washer Lower 5 638090053 E Ring 2002 2014 Cornelius Inc Continuous Flow Icemaker Installation and Service Manual Figure 32 Front End Assembly Model 1000 amp 2000 Series Exploded View and Parts List us Part No Description 638090316 Shaft Seal Seat 638090330 001 Front end Assy WCC1001 amp 2001 638090330 002 Front end Assy WCC1002 amp 2002 638090343 001 Front end Assy WCF1101 8 2201 638090343 002 Front end Assy WCF1102 amp 2202 638090000 001 Gearmotor WCC1002 amp 2002 without Service Kit 638090000 001 Gearmotor WCC1001 amp 2001 without Service Kit 638090050 001 Gearmotor Assy WCC1001 amp 2001 with Service Kit 638090050 001 Gearmotor Assy WCC10028 2002 with Service Kit 2 638090315 Shaft Seal Mount 3 1638036042 O Ring 4 638090051 Shaft Seal 5 638007301 030 Washer Lower 2002 2014 Cornelius Inc 38 Item No Part No Description 6 638090053 E Ring 7 638007106 03 Screw 1 4 x 3 4 FHSC 8 638007302 06 Washer Lock 1 4 Split 9 638007088 01 Screw 1 4 20 x 5 8 Lg HHMS 10 638090335 Evaporator Assembly 11 1638090313
18. AND ICEMAKER ASSEMBLY MopEL 1000 SERIES jud Part No Description i Part No Description 9 638036087 Clamp Dispense Tray 638090330 001 Front End Assembly 208 230V WCC1000 10 638036872 001 Dispense Tray Assembly 638090330 002 Front End Assembly 220V 50Hz 638036864 Cvr amp Detector Assembly i WCC1002 Dispense Tray 638090343 001 Front End Assembly 208 230V 638036884 Cover Dispense Tray 638090343 002 Front End Assembly 220V 50Hz 695090987 covers Dispense Tray W o Detector WCF1102 638036867 001 Clip Cover 5 638090321 Compressor 208 230V 638036884 Detector Assembly Ice Level 638090331 Compressor 220V 50Hz 12 638036020 Drop Tube Assembly 638090325 001 Electrical Box Assembly WCC1001 A 13 638090350 Water Level Control Assembly 638090325 001 Electrical Box Assembly WCC1001 W 14 638090347 Bracket Water Level Control 638090325 009 Electrical Box Assembly WCC1001 R 15 638090326 Expansion Valve 638090325 002 Electrical Box Assembly WCC1002 A 16 638007262 01 Nut Tinnerman 638090325 002 Electrical Box Assembly WCC1002 W 17 638090055 Dryer 638090325 010 Electrical Box Assembly WCC1002 R 18 638008409 Bulkhead Fitting 638090325 003 Electrical Box Assembly WCF1101 A 19 1638007206 04 Nut Bulkhead Fitting 638090325 003 Electrical Box Assembly WCF1101 W 20 638007921 Connector UL Ground 638090325 011 Electrical Box Assembly
19. Auger 12 638090317 Extruding Head Assembly Center 13 16380908318 Extruding Head Flanker 14 1638090311 Diverter Nut Assembly 15 638090319 Bearing Nylon 638090320 Bearing Delrin 16 1638090326 Expansion Valve Thermal 17 638090349 Bracket Mounting 18 638007106 03 Screw 1 4 x 3 4 FHSC Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Figure 33 Electrical Box Assembly Model 500 and 700 Series Part No 500 700 Part No 701 208 Part No 502 702 No 115V 230V 220 240V Name Qty 1 638008816 01 638008816 01 638008816 01 Electrical box 1 2 638007026 03 638007026 03 638007026 03 _ Screw 8 32 x 5 8 RHMS 2 3 638090052 638090054 638090054 Contactor 1 4 638003898 638010002 638010002 Relay 1 5 638004791 638004791 638004791 Switch Toggle 1 638036067 638036067 638036067 Bin Probe Assembly w Holder WCC 1 638036085 638036085 638036085 Bin Probe Assembly w Holder WCF 1 7 638007026 01 638007026 01 638007026 01 _ Screw 8 32 x 3 8 RHMS 2 8 638007904 01 638007904 01 638007904 01 Housing 2 Pin Recept Conn 1 9 638007903 01 638007903 01 638007903 01 Housing3 Pin Recept Conn 1 10 638004792 638004792 638004792 Indicator Plate 1 11 638007303 04 638007303 04 638007303 04 Lockwasher 1 12 638007904 01 638007904 01 638007904 01 Housing 2 Pin Recept Conn
20. Cinellus CONTINUOUS FLOW ICEMAKER 500 700 1000 2000 Series Installation and Service Manual Release Date August 1 2002 Publication Number 638085278 Revision Date March 19 2014 Revision F Visit the Cornelius web site at www cornelius com for all your Literature needs The products technical information and instructions contained in this manual are subject to change without notice These instructions are not intended to cover all details or variations of the equipment nor to provide for every possi ble contingency in the installation operation or maintenance of this equipment This manual assumes that the per son s working on the equipment have been trained and are skilled in working with electrical plumbing pneumatic and mechanical equipment It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met in addition to the information contained in this manual This Product is warranted only as provided in Cornelius Commercial Warrant applicable to this Product and is sub ject to all of the restrictions and limitations contained in the Commercial Warranty Cornelius will not be responsible for any repair replacement or other service required by or loss or damage resulting from any of the following occurrences including but not limited to 1 other than normal and proper use and normal service conditions with respect to the Product 2 improper
21. EAL REPLACEMENT 700 amp 1000 See Figure 20 1 Place the shaft seal locator seat and shaft seal mount over the gear motor output shaft and push down until the shaft seal seat and shaft seal mount rest flush on top of the gear motor 2 Place the rubber coated ceramic seal important ceramic face up over the output shaft and push down until the seal rests in the recess of the shaft seal mount lubricate the rubber on the ceramic seal with rubber lubri cant 3 Place the shaft seal with the carbon face down spring up over the output shaft and push gently downward until the seal rests on the carbon face of the output shaft seal 4 Place flat washer over the output shaft and let it rest on the output shaft seal Push down on the washer com pressing 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 UPPER NUT AND BEARING ASSEMBLY The upper white bearing located on top of the auger is used to absorb the force between the auger and extruding head NOTE The bearings are 3 32 thick When they wear below 1 16 they should be replaced Bearings to be inspected for wear during quarterly maintenance See Figure 12 To Replace Bearing A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result
22. Number 638085278 Continuous Flow Icemaker Installation and Service Manual CG GENERAL INFORMATION GENERAL DESCRIPTION This section gives the Unit description theory of operation and design data for continuous flow icemaker series 500 700 1000 and 2000 IMPORTANT To the user of this manual This manual is a guide for installing operating and maintaining this equipment Refer to the Table of Contents for page location for detailed information pertaining to questions that arise during installation operation service or maintenance of this equipment SPECIFICATION CHART i Refrigerant goe e Models Condensing VAC HZ Comp Fan GRMTR Circuit Unit PH Wire RLA Amps Amps oz Type Fuse WCC500 A Air Cooled 115 60 10 1 1 1 2 24 R404A 20 WCC500 W Water Cooled 115 60 10 1 N A 2 11 R404A 20 WCC502 A Air Cooled 220 240 50 5 3 0 5 1 6 24 R404A 20 WCC502 W Water Cooled 220 240 50 5 3 N A 1 6 11 R404A 20 WCC510 A Air Cooled 115 60 10 1 1 1 2 24 R404A 20 WCC510 W Water Cooled 115 60 10 1 N A 2 11 R404A 20 WCC512 A Air Cooled 220 240 50 5 3 0 5 1 6 24 R404A 20 WCC512 W Water Cooled 220 240 50 5 3 N A 1 6 11 R404A 20 WCC700 A Air Cooled 115 60 12 1 6 2 24 R404A 20 WCC700 W Water Cooled 115 60 12 N A 2 13 R404A 20 WCC701 A Air Cooled 208 230 60 7 7 1 6 2 24 R404A 20 WCC701 W Water Cooled 208 230 60 7 7 N A 2 13 R404A 20 WCC702 A Air Cooled 220 240 50 8 2 0 5 1 6 24 R404A 20 WCC7
23. Route incoming power in conduit through rear panel to icemaker electrical control box Make connections to wires provided in the control box and ground lug screw 2 Fused Line should be checked and sized according to electrical rating shown on unit nameplate G AUGER ENGAGEMENT 1 Becertain that auger is fully engaged to lower drive and extruding head is fully engaged into evaporator H BiN CoNTROL 1 Remove tape holding control to white ice chute and also remove control bracket mounting screw located in base of unit behind electrical box Screw will be used later to fasten bin control bracket to base of unit 2 Slide control and bracket down chute to base of unit very carefully guide control and bracket through 1 2 hole in front of ice chute Use CAUTION to be sure control goes into bin not between base of unit and bin top 3 Check location of bin control it should be directly under ice chute at a 45 angle With control in place use mounting screw that was removed in Step 1 to secure bracket to base See Figure 4 CONTROL BRACKET 12 MOUNTING SCREW ICE CHUTE BIN TOP ADAPTER CONTROL BRACKET WCC BASE Figure 4 Bin Control INITIAL START UP CHECKS AND ADJUSTMENT INSTRUCTIONS NOTE Do not start unit before completing installation steps on pages 6 through 8 Turn on water supply if unit is water cooled turn water on to condenser also turn on main power switch located on top of electrical box
24. WCF1101 R 21 638007295 Bulkhead Fitting Water Cool 638090325 004 Electrical Box Assembly WCF1102 A 22 638009711 Support Condenser Water Cooled 638090325 004 Electrical Box Assembly WCF1102 W 23 638009712 Clip Condenser Water Cooled 638090325 012 Electrical Box Assembly WCF1102 R 24 638007208 03 Nut Palnut 3 4 16 4 638036121 Condenser Air Cool 25 638090021 Valve Water Regulating 1638009776 Condenser Water Cool 26 638036188 Receiver Upright 638090344 001 Fan Motor Assembly 208 230V 27 638036194 Valve Head Pressure 2 638090344 002 Fan Motor Assembly 220V 50Hz 28 638037110 Washer Seal 638036011 Fan Blade 29 638037111 Valve Rotolock 638004391 Bracket Fan Motor 30 638036014 Cover Electrical Box 638090349 Bracket Mounting 2002 2014 Cornelius Inc 34 NOTE Not Shown Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Figure 29 Water Level Control Assembly Model WCC500 700 1000 Series Exploded View and Parts List Publication Number 638085278 35 Item ati Part No Description eh Part No Description No 63030819 Float and Stem Assembly 638030822 Reservoir Assembly WCC500 700 3 Magnet amp Bracket Assembly Reservoir Float Cover B OR 638008483 Reed Switch Assembly WCC70
25. a SAFETY INSTRUCTIONS READ AND FoLLow ALL SAFETY INSTRUCTIONS Safety Overview e Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning caution labels on the unit decals labels or laminated cards e Read and understand ALL applicable OSHA Occupational Safety and Health Administration safety regulations before operating this unit Recognition Recognize Safety Alerts A This is the safety alert symbol When you see it in this manual or on the unit be alert to the potential of personal injury or damage to the unit DIFFERENT TYPES OF ALERTS A DANGER Indicates an immediate hazardous situation which if not avoided WILL result in serious injury death or equipment damage A WARNING Indicates a potentially hazardous situation which if not avoided COULD result in serious injury death or equipment damage A CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TIPS e Carefully read and follow all safety messages in this manual and safety signs on the unit e Keep safety signs in good condition and replace missing or damaged items Learn howto operate the unit and how to use the controls properly Do not let anyone operate the unit without proper training This appliance is not intended for use by very young children or infirm persons without supervision Young children should be supervised to e
26. a ue eee 16 Refrigeration System Adjustments 16 Expansion Valve s a etse i eve PRI RR REQUE oes ip DEI pd Re Rand 16 Adjustment and Troubleshooting 16 Condenser Modulating Valve 17 Condenser Modulating Valve Hemoval ns 18 Bin Gontrol azonus anta asus a Vida e ao la ad as apes rupis us AE 18 Gear Mower 4 Ki ras ERE esa a A AY a es 19 Moto e 20 iela Bela T 20 To Replace Gear Motor Assembly 20 Installation and Shaft Seal Replacement 500 21 Auger and Extruding Head Removal 21 Installation and Shaft Seal Replacement 700 amp 1000 22 Upper Nut and Bearing Assembly aks 22 To Replace Bearing 1 u usa eda ege es rd eos e S e 22 Electrical CheckOUL p L a 205 d RE e A Ea ai ER dd mni e E 23 Overload Check cis Ran EEN E A E RENI eee Se a ae 23 Compressor Ceo ss one eme eee taret we d taeda ard a sese ed pte 23 Capacitor Check x xcov ee hU E TOU eats c ades E deeg ure e 24 Sale Gonlrols uoo Las OILS Aa A a ee Eas M tes i E EE DES ME 24 G ide to Good ICE aioe eaten EPI a a RERUM Deere x oS ene Eri eR dae 25 Troubleshoolihg EE dd TRA EE a a REY qs 27 Pans EISE iau akis te alo oua S E i er aos dw cae i e RE 28 Refrigeration and Icemaker Assembly Model 500 Series 30 Refrigeration and Icemaker Assembly Model 700 Series 32 Refrigeration and Icemaker Assembly Model 1000 Series 34 Continuous Flow Icemaker Installation and Service Manual C Ge
27. ablished by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the eguipment 1 Disconnect the transmission cable from the electrical box 2 Remove the 4 hex head bolts securing the evaporator to the top of the transmission 3 Remove the 4 bolt s holding the transmission and bracket to frame base while supporting the weight of the evaporator Remove the transmission from the unit 4 When replacing the transmission it may be necessary to rotate the auger back and forth to align the motor shaft and auger 2002 2014 Cornelius Inc 20 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Gua a E RING FL PLAIN FLAT s AUGER NUT AUGER Romei SHAFT SEAL BEARING NYLON BEARING DELRIN PE LOCATOR SEAL D DRIVE e Via GROOVE EXTRUDING HEAD GEARMOTOR ANTI ROTATION RIB 3 PLACES Figure 17 Shaft Seal 500 Figure 18 Auger and Extruding Head Removal INSTALLATION AND SHAFT SEAL REPLACEMENT 500 See Figure 18 1 Place the shaft seal locator seat over the gear motor output shaft embossed side down and push down until the shaft seal seat rests flush on top of the gear motor 2 Place the rubber coated ceramic seal important ceramic face up over the output shaft and push down until the seal rests on top of the shaft seal seat Lubricate rubber on the ceramic seal with
28. and make the following system checks NOTE If unit will not start be sure water reservoir is full Low water safety control must be properly adjusted to start and shut down unit If water level drops below bottom of reservoir unit must shut down Adjustment is made by moving magnet up or down Water Level lf necessary adjust float by bending float arm up or down as needed push float assembly down until unit stops running Release float and unit will restart Keep water in reservoir at level line while unit is in operation See Figure 5 Low Water Safety Control Adjust magnet by bending magnet arm as needed to shut unit down if water level drops below bottom of reservoir Bin Control Place ice around probe unit should shut down in one minute Remove ice from around probe unit should start in two minutes NOTE For altitudes over 1000 feet above sea level adjust range screw behind end cover Half turn max raises setting 4 F approx 2002 2014 Cornelius Inc 8 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Gua Inlet Fitting Bend up to raise water level Bend down to lower water level Bend in this direction to shut down unit sooner Figure 5 Icemaker Float Assembly Water modulating valve water cooled units only Opening point of condenser water modulating valve should be set to maintain proper operating pressure in the refrigeration system high side see char
29. e coil on the antifreeze relay along with the low water safety If the unit is water cooled the condenser high pressure cut out is also in series The Control Switch is held in place inside the electrical box by two screws Control bulb is positioned under the ice chute and can be replaced by removing the screw that holds the bracket to the base of the unit With the control and bracket removed slip the bulb off the end of the bracket The most important thing to remember when replacing the probe is to be careful not to cut or kink it and be sure the sensor bulb is located in a position to shut the unit down before ice reaches the ice chute This icemaker is also equipped with a safety ice level sensor This sensor control is located on the dispense tray cover This switch is also in series with the anti freeze relay and other safety circuitry SWITCH TERMINALS BIN CONTROL I l Figure 15 Bin Control Switch 2002 2014 Cornelius Inc 18 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Gua GEAR MOTOR The gear motor is equipped with a start relay and a manual reset overload When current is applied the relay energizes and completes the circuit to the start winding The motor reaches a predetermined speed and the relay drops out disconnecting the start winding The run winding remains in the circuit as long as current is applied The purpose of the overload is to automat
30. er temperature and air temperature from condenser inlet and determine at what pressure unit should be running Machines are equipped with thermostatic valves there is NO adjustment If correct pressure cannot be obtained first be sure system has time to stabilize 10 15 minutes Second be sure sensing bulb is located at 12 00 position on outlet side of evaporator about 3 4 inches away from evaporator and be sure to insulate well and clamp tightly to tubing If system pressures are still not adequate take a second water and air temperature reading and go over other parts of system for possible problems If proper charge is questionable evacuate and recharge to nameplate and leak check If valve still malfunctions replace valve When replacing valve be sure to bleed refrigerant gas from low side port so as not to lose refrigerant oil Use general refrigerant system practices when replacing and recharging unit After new valve is in place go through previous monitored adjustments and troubleshooting to be sure valve is functioning properly NOTE Units with thermostatic expansion valve valve is located on bottom refrigerant line Sensing bulb is located on top refrigerant line On water cooled units adjust condenser modulating valve before troubleshooting expansion valve 2002 2014 Cornelius Inc 16 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Gua A CAUTION Very high discharge pressure is present i
31. g the icemaker In addition to recommended monthly procedure and if a more frequent cleaning and sanitizing pattern has not been established unit must be cleaned and sanitized Publication Number 638085278 13 2002 2014 Cornelius Inc Cua Continuous Flow Icemaker Installation and Service Manual Semi Annually Semi Annually in addition to all previously established service procedures perform the following Check for water leaks in tube connections water fittings and lower icemaker water seal Check drain tubes for clogs and aged tubes Replace if tubes are stained or brittle Check for signs of condensation Clean where necessary and replace insulation properly Check safety circuits for proper operation Check refrigeration system see page 15 Check unit for abnormal noise Tighten machine and cabinet screws if necessary N Oo PON Check white upper bearings on auger assembly If bearings are less than 1 16 thick replace See Figure 12 REPLACE 1 16 OK REPLACE Figure 12 Upper Nut and Bearing Assembly 2002 2014 Cornelius Inc 14 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual C Ginelius gt WATER LEVEL CONTROL How WATER LEVEL CONTROL WORKS When water is introduced through the inlet fitting the float rises the float pushes against a lever which in turn forces the poppet assembly against the inlet fitting valve seat which seals the water off See F
32. ically shut off the motor in the event of a mechanical bind of the transmission an overload condition within the evaporator or an electrical malfunction It does this by sensing amperage draw If the motor stalls the start relay would energize and stay energized The amperage would surge 5 to 6 times greater than the normal draw In this event the overload would shut off the transmission in 4 to 8 seconds If the motor is subjected to an abnormal load but does not reach a stall condition the overload will react but over a greater period of time The reaction time depends upon the amperage to which it is subjected The overload through the safety circuit also shuts off the compressor GEARMOTOR OVERLOAD TRIPPED Check water level control and evaporator water tube for line build up restrictions NO CAUTION ear ice from evaporator and auger before resetting overload Reset overload IMPORTANT icemaker num runs Icemaker runs when molor goes reset but problem has not been found Continue checking for overload as follows to Short run Trips guard against future again in 2 problems minutes Check gearmotor circuits YES CLEAN See Instructions Will not Reset Overload Resets but hot try motor does again not run Will not OVERLOAD GUIDE Check reset gearmotor Replace ELECTRICAL circuits overload High or low voltage Weak power lines can cause overloads on icemakers restarts H
33. icing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the eguipment Shut off water supply to condenser and evacuate refrigerant from system Remove inlet water line from Condenser Modulating Valve Also remove tube from high side refrigerant line Remove Condenser Modulating Valve and bracket from unit Remove valve from bracket Replace Condenser Modulating Valve by reversing Steps 2 thru 4 Then pull system into vacuum Charge unit with proper amount of refrigeration Turn power and water on to unit With unit running adjust modulating valve to proper setting Dm Jm mb on o Go through a complete system check BiN CONTROL The type of bin control used on all WCC Models is thermostatically controlled The switch itself is inside the electrical box and can be serviced from the front of the unit The cap tube bulb is located directly under the ice chute To test the switch disconnect power to the unit and remove one wire from the switch Connect both leads of the ohmmeter to the Bin Control Switch terminals With the control bulb at room temperature ohmmeter should read Closed Circuit Refer to Figure 15 Cover the control bulb with ice Within one minute the switch should click and the ohmmeter should read an Open Circuit The Bin control is in series electrically with th
34. igh running current 2 4amps or above Check motor circuits and start relay Auger delay failed ICEMAKER Mechanical parts worn Scored evaporator or auger Worn thrust bearing cemaker not turning off Failed ice level control Over compression Low water inlet temperature Restrictions in water line from reservoir REFRIGERANT Contaminated charge or bad compressor Low charge or gas leak Low suction pressure Improper expansion valve Sensing bulb location or insulation and or defective expansion valve Publication Number 638085278 19 2002 2014 Cornelius Inc Gua Continuous Flow Icemaker Installation and Service Manual MOTOR CHECK The resistance readings on the winding will be between 5 to 25 ohms A meter capable of these low readings must be used The start relay cover must be removed See Figure 16 If there is no continuity on start or run winding test replace gear motor If continuity on grounded motor test replace gear motor START RELAY 1 Check between terminals 2 and 4 on relay with relay unplugged If there is continuity replace the relay as the relay contacts should be open 2 Check between terminals 3 and 4 on relay if no continuity replace the relay PIN NUMBERS Start Wht Figure 16 Gear Motor Assembly To REPLACE GEAR MOTOR ASSEMBLY A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures est
35. igure 5 Before the water inlet is sealed the safety switch is operated In the event of a water failure the float would drop down and operate the safety switch to shut off the machine If the water level control does not shut off and seal at level as indicated be sure inlet pressure does not exceed recommended factory operating range Under ordinary circumstances adjustment should not be necessary providing it was properly adjusted when the unit was installed or relocated If however the control becomes inoperative repair or replace it See Start Up Adjustment page 7 PURPOSE 1 To automatically maintain proper water level in the evaporator when unit is running and making ice 2 A safety switch is operated in the event of an interruption in water supply The switch shuts off the electrical power to the icemaker and its refrigeration system Switch will reset as soon as cause of water failure has been corrected and proper water level in icemaker has again been reached 3 The transparent bowl not only provides a visible check of water level but also is a good guide to the internal conditions which exist within the icemaker assembly itself See Cleaning Procedure To REPLACE WATER LEVEL CONTROL 1 Shut off the water supply Shut off the main power switch or unplug the ice dispenser from electrical outlet 2 Remove the flexible tubing from bottom of water level control and drain water from water level control and evap orator Rem
36. in serious injury death or damage to the equipment 1 Remove top panels 2 Remove Dispense Tray cover 3 Use an open end wrench on the auger nut connected to the bearing and turn counterclockwise to remove the assembly 4 Remove worn bearings Replace them with new bearings and then reinstall assembly 2002 2014 Cornelius Inc 22 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual C Gua NOTE If the auger turns with nut remove the cover on top of the gear motor stator and hold the motor while loosening nut GROUND Figure 20 Overload Check Figure 21 Compressor Check ELECTRICAL CHECKOUT 1 Be sure the unit is disconnected from the power source Remove the compressor electrical box cover Check for obvious damage and loose wires Disconnect the fan motor leads Since capacitors store energy short the capacitor with a screwdriver This will prevent shocks Disconnect the compressor terminal wires OVERLOAD CHECK See Figure 21 Using a volt ohmmeter check the continuity across the overload contact 1 and 3 If none wait for unit to cool down and try again If still no continuity the overload protector is defective and should be replaced CoMPRESSOR CHECK See Figure 22 The resistance readings on the windings should be between 0 25 to 10 00 ohms a meter capable of these low readings must be used 1 Check between terminals C and R Replace the compress
37. ing and Storage kid RR i a i Seve k k i a YANG RE EE 2 Mounting in or on a Counter s es esee EE 2 General Description 2 279240 rb RYE L biroi i si kai EIE ELSE 3 Specifica Om Ela EE 3 JE NEE EE 7 A Remove Icemaker from Carton E ge ees wee igo a STR Sans 7 B Cabinet Removal some em ete autre Rohe I She yee 4 BOL E 7 C Preparation of Installation Site 7 D Water Inlet HOOKUP e teg uet ee g eet E e dorem etes tede e uet dar afe He SU tu de tid 7 E Dial connection dust oss bius SA Lsd si uo o ue to bea ocu Lao dut SAMA 7 F Electrical Supply s sm Rer ERE AAA Ed e L EE acd eaaet 8 G Auger e Ee En EE 8 Ei EIER citu eerte ira ee aaa een itta Saas oa aba ia e EN ER As 8 Initial Start Up Checks and Adjustment Instructions 8 Guide O SerVIGe soil Ras E aTa tS a A a a i ARE 13 Icemaker Cleaning and Sanitizing Procedures 13 Maintenance 2 coo EE ALSS a ou a a A bo As L ts dab oi 13 Monthly du be aie Sod gud cok AER ES Ra AR pt S 13 Q anerly y uu ii ab ia Afaq a ae E a a Que as a a tok Aa tee 8 13 Semis Ally Dar rs Sa oaa Taa es ua a eee cle hota aa aeta a rs aaa 14 Water Level Conwol kius re ias pes Ne i E id ae i S 15 How Water Level Control Works Li auga uk etd diced Faw veo a wh ee a eee SEN 15 RUIDOS zurag han iu ee RI CESAR PSD oes ats San TA o Ee TTT 15 To Replace Water Level Control 15 To Replace Water Level Safety Switch liliis 15 Refrigeration System iure x emer A xe b
38. ion Valve with Service Kit 13 1638036218 Bracket Mounting Icemaker 1 638090116 Shaft Seal Seat 14 688090111 Auger Nut 999099031 Shaft Seal 15 638090119 Bearing Nylon 63800301 098 Washer Lower 16 638090120 Bearing Delrin 2002 2014 Cornelius Inc 36 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual B dy 9 e ES SS Figure 31 Front End Assembly Model 700 Series Exploded View and Parts List Publication Number 638085278 P Item Part No Description bul Part No Description No 8 6 638090216 Shaft Seal Seat 638090230 Front End Assembly WCC700 7 638007302 06 Washer Lock 1 4 Split 638090230 001 Front End Assembly WCC701 8 638007088 06 Screw 1 4 20 x 3 4 Lg HHMS 638090230 002 Front End Assembly WCC702 9 638036282 001 Evaporator Assembly 638090227 Front End Assembly WCF710 10 638090213 Auger 638090227 001 Front End Assembly WCF711 638090217 Extruding Head WCC 638090227 002 Front End Assembly WCF712 11 638090218 Extruding Head WCF 638090050 Gearmotor Assembly 700 115V 12 1638090226 Expansion Valve Thermal 638090050 004 Gearmotor Assembly 208 230V 60Hz With Service Kit 13 1638036218 Bracket Mounting 638090050 006 Gearmotor Assembly 220V 50Hz With 14 638090211 Auger Nut 1 Service Kit 15 1638090219 Bearing Nylon
39. it to freeze resulting in damage to internal components MOUNTING IN OR ON A COUNTER A WARNING When installing the unit in or on a counter top the counter must be able to support a weight in excess of 500 169lbs 700 179lbs 1000 231lbs and 2000 376lbs to insure adequate support for the unit Failure to Comply Could Result in Serious Injury Death or Equipment Damage NOTE Many units incorporate the use of additional equipment such as icemakers When any addition equipment is used you must check with the equipment manufacturer to determine the additional weight the counter will need to support to ensure a safe installation A CAUTION Very high discharges pressure is present in system Quick disconnects on your gages will minimize danger and loss of refrigerant A CAUTION Unit reguires separate electrical line See instruction manual for proper fuse size A WARNING There must be adeguate clearance around icemaker Allow minimum 6 air intake and 4 air exhaust for air exhaust and panel removal NOTE Unit must be installed per local plumbing and electrical codes See installation manual for unit reguirements Failure to do so may cause damage to unit which would void unit warranty NOTE Using any parts other than genuine factory manufactured parts relieves the manufacturer of all liability NOTE Manufacturer reserves the right to change specifications at any time O 2002 2014 Cornelius Inc 2 Publication
40. l QVOTH3AO HOLOMWHV3O N3dO HOLIMS AL33VS W83lVM MOT 391 3XVIN LON S300 ing SNO YIAVIN391 Y3MOd ON SNILV33dO LON 33 VW32I LH VHI DNILOOHSITINOYL O 2002 2014 Cornelius Inc Continuous Flow Icemaker Installation and Service Manual C gt TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring Troubleshooting Compressors Trouble Probable Cause Remedy Basically the compressor problems can be narrowed down to three areas of checkout The Compressor will not run A No voltage to the compressor A Check circuit terminals B Low voltage B Below 90 of nameplate rated voltage C Problems in the compressor C See electrical checkout electrical circuit instructions The compressor starts but trips A A Check for proper fan operation and repeatedly on the overload protector clean condenser B B Check the compressor suction and discharge pressures C Voltage C Voltage should be within 10 of the rated nameplate voltage D High compressor amperage draw D It should never exceed 120 of the rated nameplate amperage See electrical checkout instructions The compressor runs but does not A Compressor not working A Check the compressor suctions refrigerate and discharge pressures See chart on page 15 Publication Number 638085278 27 2002 2014 Cornelius Inc Continuous
41. l around the base with an NSF listed sealant 63804815B D WATER INLET HookuP 1 Water Inlet fitting is a 1 4 SAE male flare located at the rear of the unit Connect water supply with a 1 4 SAE flare nut and 1 4 copper or flexible tubing or larger 2 Water Pressure Unless otherwise specified the unit is designed to operate on water pressures between 10 P S I and 90 P S I NOTE for pressures above 90 P S I a regulator must be installed 3 Condenser Inlet Connections Use a separate 3 8 copper line or larger water line Connect to 3 8 FPT fit ting on water modulating valve 4 Filter Conditioners are recommended on supply lines to icemakers Never run the water supply to water cooled condenser through filter conditioner it uses up the cartridge unnecessarily and a saturated cartridge can starve the icemaker causing premature component damage Separate water supplies are recommended NOTE Unit must be installed per local plumbing code BOCA E DRAIN CONNECTION 1 Overflow Line is a 3 8 I D flexible tube located at the rear of the unit Extend this line to proper drain 2 Condenser Outlet is a 3 8 FPT located on the rear panel NOTE Unit must be installed per local plumbing code BOCA Publication Number 638085278 7 2002 2014 Cornelius Inc uua Continuous Flow Icemaker Installation and Service Manual F ELECTRICAL SUPPLY 1 Power Access is provided with a 7 8 dia knockout hole in the rear panel
42. n system Quick disconnects on your gauges will minimize danger and loss of refrigerant Comply with federal regulations for reclaiming refrigerant CONDENSER MODULATING VALVE The reason for using a water modulating valve is to supply the correct amount of water to the condenser and to maintain a proper operating pressure to refrigeration system high side The flow of water through the valve is increased as the high side pressure rises and is decreased as high side pressure lowers To calibrate the amount of water flow with the refrigeration system high side pressure turn adjustment screw located on end of valve opposite of bellows See Figure 14 Turn screw counterclockwise to raise opening point or clockwise to lower opening point Opening point of valve should be set to maintain proper operating pressure in refrigeration system high side Refer to Pressure Chart on page 15 Closing point of valve should be set low enough to close valve during compressor stand by periods NOTE Cold water will absorb heat faster than warm water The water flow will therefore automatically increase as inlet temperature increases p ET THERMOSTATIC po EXPANSION VALVE Figure 13 Expansion Valve Figure 14 Adjustment Screw Publication Number 638085278 17 2002 2014 Cornelius Inc Gua Continuous Flow Icemaker Installation and Service Manual CONDENSER MODULATING VALVE REMOVAL A WARNING Disconnect power to the unit before serv
43. ng cleaner mixture and reinstall in ice maker Using cleaner wipe down the dispense tray 6 Turn machine on and add cleaner solution to water level control until 2 gallons have been used 7 Turn on water supply and run machine for 15 minutes 8 Turn off machine and remove all ice 9 Sanitize using household liquid bleach 50 ppm chlorine Mixture 1 fluid ounce per gallon room temperature water 2 minute exposure time 10 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 11 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 12 If icemaker is used in conjunction with ice dispenser or storage bin follow manufacturer s recommended clean ing instructions at this time MAINTENANCE Preventive maintenance can increase the trouble free life of your icemaker Many authorized service agencies offer service contracts for your icemaker Contact your local distributor for further information Monthly 1 Clean the condenser Use a brush vacuum cleaner or blow from inside with air or CO2 gas 2 Inspect water feed reservoir at lease once a month until a definite pattern for cleaning and sanitizing has been established Quarterly This is the maximum period of time between cleaning and sanitizin
44. nsure that they do not play with the appliance e Keep your unit in proper working condition and do not allow unauthorized modifications to the unit QUALIFIED SERVICE PERSONNEL A WARNING Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY DEATH OR EQUIPMENT DAMAGE Publication Number 638085278 1 2002 2014 Cornelius Inc Gua Continuous Flow Icemaker Installation and Service Manual SAFETY PRECAUTIONS This unit has been specifically designed to provide protection against personal injury To ensure continued protection observe the following A WARNING Disconnect power to the unit before servicing following all lock out tag out procedures established by the user Verify all of the power is off to the unit before any work is performed Failure to disconnect the power could result in serious injury death or eguipment damage A CAUTION Always be sure to keep area around the unit clean and free of clutter Failure to keep this area clean may result in injury or equipment damage SHIPPING AND STORAGE A CAUTION Before shipping storing or relocating the unit the unit must be sanitized and all sanitizing solution must be drained from the system A freezing ambient environment will cause residual sanitizing solution or water remaining inside the un
45. o7 ging Buisues eA e uoisuedxe 1 doiduu ainssa1d uogons MoT wa s s abeyoas yea sef Jo efueuo MOT pue ajenoeaa jossedujoo peq Jo abieyo pajeuruejuoo onea OV 9oejdas ANVH3OIH J3H lOAJ S 1 woy eu JejeM UI uonouiseM enje1eduuej zaju Jeje MOT uoisseJduioo ISAO onuoo A 991 Dap jo Durum you Joe 99 9N Buueeq ent uJoM jene Jo 10 eJode e paJooS WOM sued jeorueuoey HWH weajs s uu s s Dog Aejap 1 6nv ejal yes pue syno 1ojouu Y90949 3ueuno 6uluuni um ebieyoos Spuet SyejsoJ Jaxeweo uo SPEOJJSAO esneo uto saul Jewod yeem aBejon moj Jo UBIH pue eui pinbi pue sql 081 OI Bum ayenoeng o abewep ayenoeng aunssaid efijeuosip 3adin9 dvOTs3AO si jene SAA JO su Ap wnwuiwu Auedoud sye Daya eoe dey 10 X90949 ooe dox Bunelado jou 2v1 JO 49949 dn azoy XL Dn au pinby uo syun uesa yy Jee 10 pebbnid payuisay Jesuapuog ajoWay uo MOT peojlano eoe deJ 19581 A jeu IIM suiejgoJd TAS sunny ysureBe pien6 yo pue uo Buijo o Jo 0 Su se peo Jano gt lt uedo uolws eunssaJd MOT 104 Bunjoeuo nunuoo n3119 Joo punoj ui Be nouo 1e86 yo uo sem ueeq jou seu w jqosd jnq JOJO UB peu Jesuepuoo UE BABA An yoy 1oJjouue 6 uiw Z u ureBe 1 s ueuM Suni Joes JOJOUI uej 0 Uejs s abseyoas usado peoye Q EECH sdi unu poys ANVLYOdINI PEN ynoslo eoujo l Ee pue ajenoe 4 ajejnsul pue SAJBA SET gt pue yea Uea apen ese Seop JOJOUI eBieupei uso jou IIM nq jesed Suni Joxeujoo DOEN E
46. or if there is no continuity the run windings are open Check between terminals C and S Replace the compressor if there is no continuity the start windings are open Check between terminals C and R or S and the shell of the compressor If there is continuity replace the compressor the motor is grounded Check between screw terminal on the overload and C on the compressor Check and repair the lead or con nections if there is no continuity Publication Number 638085278 23 2002 2014 Cornelius Inc Gua Continuous Flow Icemaker Installation and Service Manual CAPACITOR CHECK 1 Check or replace the starting capacitor disconnect the bleed resistor before checking for a shorted capacitor 2 Check or replace the run capacitor if supplied check for a shorted capacitor or either terminal grounded to case Je d GEAR MOTOR OVERLAY Figure 22 Gear Motor Overload SAFETY CONTROLS Your icemaker unit has several safety and control devices incorporated into its design A WARNING None of the described devices listed below should ever be bypassed to allow the unit to function The safety and control system shut off devices are Low water shut off reed switch located in icemaker float assembly Automatic reset type See Figure 5 Gear motor thermal overload manual reset type
47. ove flexible tubing at bottom of water level bowl connected to the overflow Hold water inlet fitting with proper tool to prevent it from rotating when disconnecting the water inlet Remove the wing nut holding the water control to its mounting bracket Control can be removed by lifting straight up To REPLACE WATER LEVEL SAFETY SWITCH 1 Shut off the main power switch or unplug the ice dispenser from electrical outlet 2 Unplug molex connector connecting switch to electrical box 3 Remove the two 2 screws anchoring the water level safety switch to the bottom of the water level control mounting bracket Publication Number 638085278 15 2002 2014 Cornelius Inc C G lt Continuous Flow Icemaker Installation and Service Manual REFRIGERATION SYSTEM 10 Ibs Discharge Pressure REFRIGERANT Water Temperature F TYPE R404A WCC 500 WCC 700 WCC 1000 WCC 2200 40 65 90 40 65 90 40 65 90 40 65 90 50 162 166 168 174 177 180 170 171 172 200 201 203 60 188 192 194 202 205 208 198 199 200 218 219 220 70 214 218 220 230 233 236 226 227 228 251 253 254 80 245 249 251 265 269 272 261 263 264 297 298 300 90 275 279 281 300 304 307 296 298 299 308 330 332 100 309 313 315 328 334 340 324 328 332 362 364 366 Air Temperature F NOTE Thermostatic Expansion valve is non adjustable on all models REFRIGERATION SYSTEM ADJUSTMENTS A complete understanding of
48. pense Tray 638036867 001 Clip Cover 16 638036366 x Drop Tube 17 638036269 Clamp Dispense Tray 18 638036869 002 Dispense Tray Assembly 19 1638031762 Gasket Foam 20 638007383 Access Port 21 1638007385 Replacement Cap 22 638036884 Detector Assembly Ice Level 23 638007208 03 Nut Palnut 3 4 16 24 638007295 Bulkhead Fitting Water Cool 25 638009755 Pressure Switch 26 638036386 Finger Guard Fan 27 638090021 Water Regulating Valve 28 638036391 Exhaust Fan Assembly 638090128 Compressor Electrical Box Assembly wae WCC500 WCF510 638090128 002 Compressor Electrical Box Assembly WCC502 WCF512 30 638090122 Relay Start 115V 31 638090132 Relay Start 220V 50Hz 32 638090124 Capacitor Start 115V 33 638090134 Capacitor Start 220V 50Hz 34 638090123 Capacitor Run 115V 37 638036267 Fan Shroud NOTE Not Shown Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual Gua 6 Right Side View 15 Figure 27 Refrigeration and Icemaker Assembly Model 700 Series Publication Number 638085278 31 O 2002 2014 Cornelius Inc C Gne gt REFRIGERATION AND ICEMAKER ASSEMBLY MopEL 700 SERIES Continuous Flow Icemaker Installation and Service Manual Item No Part No Description 638090230 Front End Assembly 115V 638090230 001 Front End Assembly 208 230V 638090230 002 Front End Assembly 220V 50Hz 63809
49. red button on motor See Figure 22 Compressor thermal overload automatic reset type See Figure 20 Anti freeze relay and associated circuit See wiring diagrams Figure 7 Figure 8 Figure 9 and Figure 10 Main service switch located on top of the control box See Figure 15 Bin Control See Figure 15 High pressure cut out water cooled only SD Qr de sp o c 2002 2014 Cornelius Inc 24 Publication Number 638085278 Continuous Flow Icemaker Installation and Service Manual GUIDE TO GOOD ICE CUSTOMER COMMENTS It runs but the ice is too soft The icemaker is not producing enough ice The ice is too wet It makes too much noise With this comment the ice is usually extremely hard and larger than normal Publication Number 638085278 Over Compression CHECK ICEMAKER LOCATION CONDITIONS FIRST Proper air flow for condens ing system Location too close to high units such as coffee urns deep fryers grills etc Supply water conditions Water too warm above 90 F Water artificially softened above 262 ppm sodium chlo ride Normal water supply too high in total dissolved solids above 500 PPM Check to see if noise objection is normal fan and air flow noise Supply water conditions Water too cold below 50 F Possibly running from pre cooler Obstructions partially blocking ice exit from top of evaporator Check fan and fan shroud 25 CG
50. rubber lubricant 3 Place the shaft seal wit the carbon face down spring up over the output shaft and push gently downward until the seal rests on the ceramic face of the output shaft seal 4 Place flat washer over the output shaft and let it rest on the output shaft seal Push down on the washer com pressing 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 AND ExTRUDING HEAD REMOVAL A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the eguipment 1 Remove the storage container cover and put it aside 2 Turn off the water supply to the icemaker 3 After the ice has melted from the head take hold of the auger nut and lift straight up to disengage from the ice maker 4 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 See Figure 18 Publication Number 638085278 21 2002 2014 Cornelius Inc C eua Continuous Flow Icemaker Installation and Service Manual S E RING TN WASHER PLAIN FLAT SHAFT SEAL MOUNT SHAFT SEAL SEAT SHAFT SEAL GEARMOTOR Figure 19 Shaft Seal 700 and 1000 INSTALLATION AND SHAFT S
51. t on page 15 Closing point of valve should be set low enough to close valve during compressor stand by periods To raise turn counterclockwise to lower turn clockwise NOTE If any of these checks or adjustments cannot be achieved refer to Troubleshooting Section of this manual or call for factory assistance at 1 800 Service BLK BLK S E x ul 2 15 RED m x 4 2 ree g E g x x x x m ANTI FREEZE o a RELAY E z zo o lt o e 4 m L sel o S Li mem t A E od 8 gt E a S BA z x y 443 5 k 2 E nuc ON OFF O Fo m a SWITCH z i Lo E M x z o 0 MES Fi a o a EE Y B 868 E o G a a 9 x W EZ lt u o z a zo x x a 8 s EZ 53 SE Ke ER zo rt gt EI RED Eu Ze L L se Y RED m Figure 6 Schematic and Wiring Diagram WCC2001 A and WCF2201 A Publication Number 638085278 9 2002 2014 Cornelius Inc C eua Continuous Flow Icemaker Installation and Service Manual BLACK y r BIN lt CONTROL SWITCH ES a SC DESCH LOW WATI SAFETY Set m WATER v COOLED e 115 VAC ONLY Be SWITCH L SERVICE SWITCH TT AUX BIN CONTROL SWITCH L
52. umber 638085278 C ines gt Continuous Flow Icemaker Installation and Service Manual pa 22 00 pa 24 00 i BACK VIEW AIR COOLED 27 00 ELECTRICAL 7 8 DIA WATER UB 1 4 MALE FLARE DRAIN 3 8 ID TYGON TUBE 2 25 2 25 m 0 94 43 94 FRONT SIDE REMOTE UN DISCHARGE LINE 112 PUNCTURE FITTING WIC INLET STI AIR EXHAUST WIC OUTLET 3 8 FPT OR BIN CONTROL PROBE REMOTE COND LIQ LINE ek POWER INL 3 8 PUCTURE FITTING ICE DISCHARGE 7 8 DIA DRAIN 3 8 ID TUBE WATER INLET 1 4 MALE FLARE 9 04 i T D 4 50 L 249 1 Rel HE cod 87 2504 2 06 1 88 m i BOTTOM VIEW VIEWED FROM BOTTOM OF MACHINE Figure 2 Series 1000 Dimension Drawing Shipping Wt Approx 120 Ibs Publication Number 638085278 5 2002 2014 Cornelius Inc Gua Continuous Flow Icemaker Installation and Service Manual 30 00 Sa pe cedes om Ree WS Hig Y Galijai die j 1 WATER IN ELECTRICAL 7 8 DIA 28 06 DRAIN 3 8 I D TUBE 2 06 pe 24 00 wl CE DISCHARGE BIN CONTROL PROBE po SAT 9 50 ra 20 13 SIDE BOTTOM BOTTOM VIEW VIEWED FROM BOTTOM OF MACHINE Figure 3 Series WCC2001 A and WCF2201 A Dimension Drawings O 2002 2014 Cornelius Inc 6 Publication Number
53. voltage 3 inadequate wiring 4 abuse 5 accident 6 alteration 7 misuse 8 neglect 9 unauthorized repair or the failure to utilize suitably qualified and trained per sons to perform service and or repair of the Product 10 improper cleaning 11 failure to follow installation oper ating cleaning or maintenance instructions 12 use of non authorized parts i e parts that are not 100 compatible with the Product which use voids the entire warranty 13 Product parts in contact with water or the product dispensed which are adversely impacted by changes in liquid scale or chemical composition Contact Information To inquire about current revisions of this and other documentation or for assistance with any Cornelius product con tact www cornelius com 800 238 3600 Trademarks and Copyrights This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius Printed in U S A TABLE OF CONTENTS Safety Instructions eoe ede EI eie o S a ida eet E quia 1 Read and Follow ALL Safety Instructions 1 Safet OVOrVIGW weise sud adios Qut ede e bte ei dot GO eth Eee eed iba erae UE 1 Ee Lu le EE 1 Different Types or Alerts e d E Boe hex wes ee ELE 1 Safely TIPS 4 29 dorm VA M RS wy wor maar e aT Vs cup A 1 Qualified Service Personnel osi ducet ns tbe rhe on dos ORE S ORTI ME TS RR d ve 1 Safety Precautions ee a qu ede esi eS PE EN 2 Shipp

CONTINUOUS FLOW ICEMAKER

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