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®
CONTINUOUS FLOW ICEMAKER
500, 700, 1000, 2000 - Series
Service Manual
Release Date: May 27, 2004
Publication Number: 630460174SER
Revision Date: February 1, 2005
Revision: C
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
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CONTINUOUS FLOW ICEMAKER SERVICE MANUAL 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 varia- tions of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, p
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Continuous Flow Icemaker Service Manual Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Read and Follow all Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Recognize Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Continuous Flow Icemaker Service Manual Publication Number: 630460174SER - ii - © 2004-2005, IMI Cornelius Inc.
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Continuous Flow Icemaker Service Manual SAFETY SAFETY INSTRUCTIONS Read and Follow all Safety Instructions Read and follow all safety instructions in this manual and on the machine (decals, labels, and laminated cards). Read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regula- tions before operating the machine. Recognize Safety Alerts This is the safety alert symbol. When you see it in this manual or on the machine be alert to the potential of perso
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Continuous Flow Icemaker Service Manual GENERAL DESCRIPTION This section gives the Unit description, theory of operation, and design data for continuous flow icemaker series 500, 700, 1000, and 2000. SPECIFICATION CHART GRMT Refrigerant Condensing Comp. Fan Circuit Models VAC HZ PH Wire R Unit RLA Amps Fuse Oz. Type Amps WCC500-A Air Cooled 115 60 1 2 10.1 1.1 2 24 R404A 20 WCC500-W Water Cooled 115 60 1 2 10.1 N/A 2 11 R404A 20 WCC502-A Air Cooled 220/240 50 1 2 5.3 0.5 1.6 24 R404A 20 WCC502-
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Continuous Flow Icemaker Service Manual 25.00 1.38 14.50 1.75 INLET 3/8 FLARED WATER COOLED ONLY OUTLET 3/8 FLRE WATER COOLED ONLY 24.50 DRAIN 3/8 ID TYGON TUBE 10.15 WATER IN 1/4 FLARE ELECTRIC 7/8 DIA 1.50 2.12 1.81 FRONT 2.50 SIDE 1.19 BACK VIEW AIR OR WATER COOLED FRONT ICE DISCHARGE 3.50 FIGURE 1. SERIES 500 & 700 DIMENSION DRAWING (SHIPPING WT. 160 LBS. APPROX). 24.00 22.00 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 0.94 1
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Continuous Flow Icemaker Service Manual 18.13 30.00 WATER IN ELECTRICAL 7/8 DIA. 28.06 23.50 DRAIN 3/8 I.D. TUBE AIR INLET 2.25 BACK FRONT 2.06 24.00 ICE DISCHARGE 9.50 2.06 20.13 FRONT 2.06 3.81 SIDE BOTTOM VIEWED FROM BOTTOM OF MACHINE FIGURE 3. SERIES WCC2001-A AND WCF2201-A DIMENSION DRAWINGS Publication Number: 630460174SER - 4 - © 2004-2005, IMI Cornelius Inc.
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Continuous Flow Icemaker Service Manual BIN CONTROL The type of bin control used on all WCC & WCF Models is an electronic control. The control is supplied with power to terminals X1 and X2. Terminals X3 and X4 are a normally closed switch which open when the thermostat sensor bulb senses ice. The sensing element is located in a 5/16” stainless steel tube which hangs from the BIN CONTROL SWITCH TERMINALS dispense tray cover down through the center of the drop tube. To test switch, start
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Continuous Flow Icemaker Service Manual CLEANING AND SANITIZING 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 machine off. 2. Shut off water supply. 3. Remove ice from storage bin. 4. Mix approved cleaner (2 gallons as directed). Recommended cleaner: Calgon Nickel-Safe, ice machine cleaner. Mixture: 3 ounces per gallon of water. 5. Clean auger/diverter assembly and ice tr
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Continuous Flow Icemaker Service Manual SEMI-ANNUALLY Semi–Annually in addition to all previously established service procedures perform the following: 1. Check for water leaks in tube connections, water fittings and lower icemaker water seal. 2. Check drain tubes for clogs and aged tubes. Replace if tubes are stained or brittle. 3. Check for signs of condensation. Clean where necessary and replace insulation properly. 4. Check safety circuits for proper operation. 5. Check refrigeration system.
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Continuous Flow Icemaker Service Manual 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. 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 water level control w
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Continuous Flow Icemaker Service Manual ELECTRICAL FIGURE 6. SCHEMATIC AND WIRING DIAGRAM WCC2001-A AND WCF2201-A FIGURE 7. SCHEMATIC AND WIRING DIAGRAM WCC500-A, WCC500-W, WCC700-A, WCC700-W, WCF510-A, WCF510-W, WCF710-A, & WCF710-W © 2004-2005, IMI Cornelius Inc. - 9 - Publication Number: 630460174SER
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Continuous Flow Icemaker Service Manual FIGURE 8. SCHEMATIC AND WIRING DIAGRAM WCC701-A, WCC701-W, WCC1001-A, WCC1001-W, WCF711-A, WCF711-W, WCF1101-A, & WCF1101-W FIGURE 9. SCHEMATIC AND WIRING DIAGRAM WCF1101R, WCC1001R, WCF1102R, & WCC1102R Publication Number: 630460174SER - 10 - © 2004-2005, IMI Cornelius Inc.
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Continuous Flow Icemaker Service Manual FIGURE 10. SCHEMATIC AND WIRING DIAGRAM WCC502, WCC702, WCC1002, WCF512, WCF712, & WCF1102 FIGURE 11. SCHEMATIC AND WIRING DIAGRAM WCC2001-R AND WCF2201-R © 2004-2005, IMI Cornelius Inc. - 11 - Publication Number: 630460174SER
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Continuous Flow Icemaker Service Manual REFRIGERATION SYSTEM Thermostatic Expansion Valve NO Adjustment. +/- 10 lbs. Discharge Pressure Water Temperature WCC 500 WCC 700 WCC 1000 WCC 2200 40° 65° 90° 50° 65° 90° 50° 65° 90° 50° 65° 90° 50° 162 166 168 60° 177 180 60° 171 172 60° 201 203 60° 188 ‘92 194 70° 205 208 70° 199 200 70° 219 220 70° 214 218 220 80° 233 236 80° 227 228 80° 253 254 80° 245 249 251 90° 269 272 90° 263 264 90° 298 300 90° 275 279 281 100° 304 307 100° 298 299 100° 330 332 1
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Continuous Flow Icemaker Service Manual 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
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Continuous Flow Icemaker Service Manual CONDENSER MODULATING VALVE REMOVAL 1. Disconnect power to unit, then shut off water supply to condenser and evacuate refrigerant from system. 2. Remove inlet water line from Condenser Modulating Valve. Also remove tube from high side refrigerant line. 3. Remove Condenser Modulating Valve and bracket from unit. 4. Remove valve from bracket. 5. Replace Condenser Modulating Valve by reversing Steps 2 through 4. Then pull system into vacuum. 6. Charge unit
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Continuous Flow Icemaker 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. If no continuity on start or run winding test, replace gearmotor. If continuity on grounded motor test, replace gearmotor. START RELAY 1. Check between “2” and “4” on relay (with relay unplugged). If there is continuity replace the relay, as the relay contacts should be open. 2. Check
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Continuous Flow Icemaker Service Manual INSTALLATION AND SHAFT SEAL REPLACEMENT 500 1. Place shaft seal locator seat over gear motor output shaft, embossed side down, and push down until shaft seal seat rests flush on top of gear motor. 2. Place rubber coated ceramic seal E–RING (important: ceramic face up) over output WASHER, PLAIN FLAT shaft and push down until seal rests on top of the shaft seal seat. (Lubricate rubber on SHAFT SEAL ceramic seal with rubber lubricant.) LOCATOR SEAL 3.
