CONTINUOUS FLOW ICEMAKER Installation and Service Manual 500-Series 700-Series 1000-Series 2000-Series Distributed By: Commercial Refrigeration Service, Inc. WWW.WorldRestaurantSupply.COM toll free (866) Ice Maker (623) 869-8881 Part No. 638085278 August 1999 Revision C THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC; 1997--99 PRINTED IN U.S.
TABLE OF CONTENTS Page SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 RECOGNIZE SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 UNDERSTAND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FOLLOW SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page AUGER AND EXTRUDING HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION AND SHAFT SEAL REPLACEMENT 700 & 1000 . . . . . . . . . . . 21 21 UPPER NUT AND BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 TO REPLACE BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ELECTRICAL CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) Page FIGURE 19. SHAFT SEAL 700 & 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 20. OVERLOAD CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 22 FIGURE 21. COMPRESSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 FIGURE 22. GEAR MOTOR OVERLOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FIGURE 23.
SAFETY INFORMATION Recognize Safety Information This is the safety-alert symbol. When you see this symbol on our machine or in this manual, be alert to the potential of personal injury. Follow recommended precautions and safe operating practices. Understand Signal Words A signal word - DANGER, WARNING, CAUTION is used with the safety-alert symbol. DANGER identifies the most serious hazards. Safety signs with signal word DANGER or WARNING are typically near specific hazards.
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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.
25.00 14.50 1.38 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 1.81 FRONT 2.12 2.50 SIDE 1.19 BACK VIEW AIR OR WATER COOLED FRONT BIN CONTROL PROBE 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 13.
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 BIN CONTROL PROBE 9.50 2.06 20.13 3.81 FRONT 2.06 SIDE BOTTOM VIEWED FROM BOTTOM OF MACHINE FIGURE 3.
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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.
F. ELECTRICAL SUPPLY 1. Power Access— is provided with a 7/8? dia. knockout hole in the rear panel. 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 Be certain that auger is fully engaged to lower drive and extruding head is fully engaged into evaporator. H. BIN CONTROL 1.
NOTE: For altitudes over 1000 feet above sea level, adjust range screw (behind end cover). Half turn max. raises setting 4_F approx. 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 chart on page 16). Closing point of valve should be set low enough to close valve during compressor stand by periods.
BLACK C S R COMPRESSOR BIN CONTROL SWITCH SERVICE SWITCH HIGH PRES. CUTOUT SWITCH AUGER GEAR MOTOR AUX BIN CONTROL SWITCH RUN CAP. 115 VAC 1 2 5 START CAP. WATER COOLED ONLY LOW WATER SAFETY SWITCH START RELAY 7 4 FAN MOTOR A B WHITE FIGURE 7. SCHEMATIC AND WIRING DIAGRAM WCC500--A, WCC500--W, WCC700--A, WCC700--W, WCF510--A, WCF510--W, WCF710--A, & WCF710--W BLACK COMPRESSOR C S R BIN CONTROL SWITCH LOW WATER SAFETY SWITCH HIGH PRES.
RED COMPRESSOR 5 2 C 1 R RUN CAP S START CAP START RELAY LOW PRESSURE CONTROL GEAR MOTOR MAIN CONTACTOR BIN CONTROL MCC1001R SOLENOID CRANK CASE HEATER 4 7 PUMP DOWN SWITCH 208/230 VAC ANTI--FREEZE RELAY AUX BIN CONTROL ON/OFF SWITCH WATER LEVEL BLK TO COMPRESSOR MCC701R FIGURE 9. SCHEMATIC AND WIRING DIAGRAM WCF1101R, WCC1001R, WCF1102R, & WCC1102R FIGURE 10.
638085278 FIGURE 11.
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 machine off. 2. Shut off 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.
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 (see page 16). 6. Check unit for abnormal noise.
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 Figure 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.
REFRIGERATION SYSTEM NOTE: Thermostatic Expansion Valve NO Adjustment – 10 lbs.
CAUTION: Very high discharge pressure is present in 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.
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 switch, disconnect power to unit and remove one wire from switch. Connect both leads of your ohmmeter to the Bin Control Switch terminals. With control bulb at room temperature ohmmeter should read “Closed Circuit”.
GEARMOTOR OVERLOAD TRIPPED Check water level control and evaporator water tube for line build-up restrictions. NO YES CAUTION Clear ice from evaporator and auger before resetting overload. CLEAN See Instructions. 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. Short run. Trips again in 2 minutes. Check gearmotor circuits. Resets but motor does not run.
FIGURE 16. GEARMOTOR ASSEMBLY TO REPLACE GEARMOTOR ASSEMBLY 1. Disconnect the icemaker from the electrical power source. 2. Disconnect the transmission cable from the electrical box. 3. Remove the 4 hex head bolts securing the evaporator to the top of the transmission. 4. 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. 5.
2. Place rubber coated ceramic seal (important: ceramic face up) over output shaft and push down until seal rests on top of the shaft seal seat. (Lubricate rubber on ceramic seal with rubber lubricant.) 3. Place shaft seal with carbon face down (spring up) over output shaft and push (gently) downward until seal rests on ceramic face of the output shaft seal. 4. Place flat washer over output shaft and let rest on the output shaft seal. Push down on the washer compressing the spring on the output shaft seal.
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 1. Disconnect unit from electric power. 2. Remove top panels. 3. Remove Dispense Tray Cover. 4. Use an open end wrench on auger nut connected to bearing and turn counterclockwise to remove assembly. 5. Remove worn bearings. Replace with new bearings and then reinstall assembly.
CAPACITOR CHECK 9. Check or replace start capacitor, disconnect bleed resistor before checking for shorted capacitor. 10. Check or replace run capacitor (if supplied) check for shorted capacitor or either terminal grounded to case. GEAR MOTOR OVERLAY FIGURE 22. GEAR MOTOR OVERLOAD SAFETY CONTROLS Your icemaker unit has several safety and control devices incorporated into its design. WARNING: None of the below described devices should ever be “bypassed” to allow the unit to function.
GUIDE TO GOOD ICE CUSTOMER COMMENTS CHECK ICEMAKER LOCATION CONDITIONS FIRST “It runs but the ice is too soft.” S Proper air flow for condensing system. “The icemaker is not producing enough ice.” S Location too close to high units such as coffee urns, deep fryers, grills, etc. “The ice is too wet.” S Supply water conditions Water too warm (above 90_F). Water artificially softened above 262 ppm sodium chloride. Normal water supply too high in total dissolved solids (above 500 PPM).
TROUBLESHOOTING CHART -- ICEMAKER NOT OPERATING NO POWER Check electrical wiring in control box for loose connections. Check for failed service switch or relay. Check power to machine. High pressure switch open or cycling on and off. LOW WATER SAFETY SWITCH OPEN ICEMAKER RUNS BUT DOES NOT MAKE ICE Remote condenser units only Condenser fan running but compressor not running Check electrical wiring in control box for loose connections. Check power to condenser.
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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 THE COMPRESSOR STARTS BUT TRIPS REPEATEDLY ON THE OVERLOAD PROTECTOR THE COMPRESSOR RUNS BUT WILL NOT REFRIGERATE A. No voltage to the compressor terminals. A. Check circuit. B. Low voltage. B.
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PARTS LIST 29 638085278
9 10 7 6 2 4 3 11 1 FIGURE 23.
FIGURE 24.
REFRIGERATION AND ICEMAKER ASSEMBLY MODEL 500 SERIES Item No. 18 Part No. 638090130 Front End Assembly--WCC500 638090130--002 Front End Assembly--WCC502 638090143 638090143--002 19 638090121 638090131 20 Description 638036295--01 638036295--03 Item No. Part No.
FIGURE 25.
REFRIGERATION AND ICEMAKER ASSEMBLY MODEL 700 SERIES Item No. 1 Part No. 638090230 Front End Assembly--115V 638090230--001 Front End Assembly--208/230V 638090230--002 638090227 638090227--001 638090227--002 2 638090221 638090241 3 Item No. Part No.
FIGURE 26.
REFRIGERATION AND ICEMAKER ASSEMBLY MODEL 1000 SERIES Item No. Part No.
3 2 1 5 6 4 7 FIGURE 27.
16 14 16 10 9 8 7 6 4 3 5 2 1 FIGURE 28. FRONT END ASSEMBLY MODEL 500 SERIES EXPLODED VIEW AND PARTS LIST Item No. Part No. Name Item No. Part No. Name 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.
16 16 14 10 9 8 7 6 4 3 5 2 1 FIGURE 29. FRONT END ASSEMBLY MODEL 700 SERIES EXPLODED VIEW AND PARTS LIST Item No. Part No. Item No. Part No. Name 638090230 Front End Assembly--WCC700 4 638007301--030 Washer, Lower 638090230--001 Front End Assembly--WCC701 5 638090053 E-Ring 638090230--002 Front End Assembly--WCC702 6 638090216 Shaft Seal Seat Front End Assembly--WCF710 7 638007302--06 Washer, Lock 1/4 Split Front End Assembly--WCF711 8 638007088--06 Screw 1/4-20 x 3/4 Lg.
FIGURE 30. FRONT END ASSEMBLY MODEL 1000 & 2000 SERIES EXPLODED VIEW AND PARTS LIST Item No. 17 1 Part No. Item No. Part No. Name 638090316 Shaft Seal Seat 6 638090053 E-Ring 638090330--001 Front end Assy--WCC1001 & 2001 7 638007106--03 Screw 1/4 x 3/4 FHSC 638090330--002 Front end Assy--WCC1002 & 2002 8 638007302--06 Washer Lock 1/4 Split 638090343--001 Front end Assy--WCF1101 & 2201 9 638007088--01 Screw, 1/4-20 x 5/8 Lg.
9 11 10 12 8 5 6 7 4 1 3 2 FIGURE 31. ELECTRICAL BOX ASSEMBLY MODEL 500 AND 700 SERIES Item No. Part No. 500/700 (115V) Part No. 701 (208/230V) Part No.
5 4 2 3 6 1 15 7 14 16 8 12 13 17 11 9 10 FIGURE 32. ELECTRICAL ASSEMBLY MODEL 1000 AND 2000 SERIES Part No Item No 1 Name 638090322 Start Relay, 208/230 60 Hz. WCC1001 and WCF1101 638090242 Start Relay, 220V 50 Hz. WCC1002 and WCF1102 40285 Start Relay, 208/230 60 Hz. WCC2001 and WCF2201 161998013 Start Relay, 220 50 Hz. WCC2002 and WCF2202 2 638090054 Contactor, 208/230 50/60 Hz 3 63800726605 Nut, Tinnerman 4 638090323 Capacitor Run, 208/230 V 60 Hz.
IMI CORNELIUS WILSHIRE CERTIFICATE OF WARRANTY TWO YEAR LIMITED ICE EQUIPMENT WARRANTY IMI Cornelius Wilshire (formerly Wilshire Corp., Selmix Reynolds Products, Alco Dispensing Canada Ltd.
IMI CORNELIUS INC.
