CONTINUOUS FLOW ICEMAKER 500, 700, 1000, 2000 - Series Service Manual Release Date: May 27, 2004 Publication Number: 630460174SER Revision Date: April 07, 2014 Revision: J 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 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, pneumatic, and mechanical equipment.
TABLE OF CONTENTS Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Shaft Seal Replacement 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Auger and Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Auger Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installation and Shaft Seal Replacement 700 & 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuous Flow Icemaker Service Manual SAFETY INSTRUCTIONS READ AND FOLLOW ALL SAFETY INSTRUCTIONS Safety Overview • Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or laminated cards). • Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before operating this unit. Recognition Recognize Safety Alerts ! This is the safety alert symbol.
Continuous Flow Icemaker Service Manual SAFETY PRECAUTIONS This unit has been specifically designed to provide protection against personal injury. To ensure continued protection observe the following: ! 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 equipment damage.
Continuous Flow Icemaker Service Manual 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. SPECIFICATION CHART Models Condensing Unit VAC HZ PH Wire Comp. RLA Fan GRMTR Amps Amps Refrigerant Oz. Type Circuit Fuse WCC500-A Air Cooled 115 60 1 2 10.5 1.1 2 20 R404A 20 WCC500-W Water Cooled 115 60 1 2 10.
Continuous Flow Icemaker Service Manual Temperature Chart Figure 1. Series 500 & 700 Dimension Drawing (Shipping Wt. 160 Lbs. Approx). Publication Number: 630460174SER -4- © 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual AIR INLET AIR EXHAUST 24.00 22.00 W/C INLET 3/8"F PT 27.00 W/C OUTLET 3/8" F PT REMOTE COND .LIQ.LINE 3/8 PUNCTURE FITTING (REMOTE) DISCHARGE LINE 1/2 PUNCTURE FITTING RECEPTACLE DRAIN 3/8" ID TUBE POWER INLET 7/8"DIA FRONT WATER INLET 1/4" MALE FLARE BACK SIDE ICE DISCHARGE 2.06 5.87 9.04 BOTTOM VIEW (VIEWED FROM BOTTOM OF VIEW) Figure 2. Series 1000 Dimension Drawing (Shipping Wt. 210 Lbs. Approx). © 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual 18.13 30.00 WATER IN ELECTRICAL 7/8 DIA. 28.06 23.50 AIR INLET DRAIN 3/8 I.D. TUBE 2.25 BACK FRONT 2.06 24.00 ICE DISCHARGE 9.50 2.06 20.13 3.81 FRONT 2.06 SIDE BOTTOM VIEWED FROM BOTTOM OF MACHINE Figure 3. Series WCC2001-A and WCF2201-A Dimension Drawings Publication Number: 630460174SER -6- © 2004-2014, Cornelius Inc.
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 dispense tray cover down through the center of the drop tube.
Continuous Flow Icemaker Service Manual CLEANING AND SANITIZING ICEMAKER CLEANING AND SANITIZING PROCEDURES ! 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 equipment. ! WARNING: Do not use any of the ice made during cleaning operations. Clean and sanitize ice storage area when cleaning icemaker.
Continuous Flow Icemaker Service Manual Quarterly This is the maximum period of time between cleaning and sanitizing 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. 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.
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.
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 © 2004-2014, Cornelius Inc.
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 - 12 - © 2004-2014, Cornelius Inc.
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 © 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual REFRIGERATION SYSTEM REFRIGERATION SYSTEM ADJUSTMENTS A complete understanding of 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.
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.
Continuous Flow Icemaker Service Manual GEARMOTOR OVERLOAD TRIPPED Check water level control and evaporator water tube for the build-up restrictions CAUTION CLEAN Clear ice from Evaporator and Auger before Resetting overload See Instruction Reset Overload IMPORTANT Icemaker runs when Reset but problem has Not been found Continue checking for Overload as follows to Guard against future problems Icemaker runs Reset but Motor does Not run Short run. Trips Again in 2 Minutes.
Continuous Flow Icemaker Service Manual START RELAY ! 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 equipment. 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.
Continuous Flow Icemaker Service Manual AUGER NUT AUGER BEARING NYLON BEARING DELRIN “D” DRIVE GROOVE EXTRUDING HEAD ANTI–ROTATION RIB – 3 PLACES Figure 15. Auger and Extruding Head Removal 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.
Continuous Flow Icemaker Service Manual Auger/ Extruder Head Figure 17. 2. When the auger is lowered into the evaporator, rotate the auger to engage the motor drive shaft, see Figure 18. Extruder Head Evaporator Figure 18. 3. Carefully rotate the extruder head until the tabs on the extruder head drop into the slots on the evaporator plate, as shown in Figure 19.
Continuous Flow Icemaker Service Manual Failure to lock the extruder head tabs into the evaporator slots causes the auger to be out of proper alignment with the evaporator. This may cause excessive loads on the auger that can potentially result in excessive noise and tripping the drive motor overload. All tabs & slots engaged Figure 19. INSTALLATION AND SHAFT SEAL REPLACEMENT 700 & 1000 1.
Continuous Flow Icemaker Service Manual Failure to comply could result 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 auger nut connected to bearing and turn counterclockwise to remove assembly. 4. Remove worn bearings. Replace with new bearings and then reinstall assembly. NOTE: If auger turns with nut, remove cover on top of gearmotor stator and hold motor while loosening nut.
Continuous Flow Icemaker Service Manual The resistance readings on the windings will be between 0.25 to 10.00 ohms, a meter capable of these low readings must be used. 1. Check between “C” and “R.” Replace the compressor if there is no continuity as the run windings are open. 2. Check between “C” and “S.” Replace the compressor if there is no continuity as the start windings are open. Figure 22. Compressor Check 3. Check between “C” and “R” or “S” and the shell of the compressor.
Continuous Flow Icemaker Service Manual 5. Main service switch located on top of the control box. 6. Bin Control. 7. High pressure cut out (water cooled only). GUIDE TO GOOD ICE © 2004-2014, Cornelius Inc.
Figure 21. Troubleshooting Chart Continuous Flow Icemaker Service Manual Publication Number: 630460174SER - 24 - © 2004-2014, Cornelius Inc.
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