® CORNELIUS ICE MAKERS Training Manual IMD 600-90 Front End Assembly Release Date: March 14, 2003 Publication Number: TP00967 Revision Date: June 18, 2003 Revision: B Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
CORNELIUS ICE MAKERS TRAINING 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 variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preview Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Things To Know / Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Popular Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix B — Evolution of the Chunklet / Flaker Design . . . . . . . . . . . . . . . . . . . . The Spline Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Pin Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Generation “D” Drive . . . . . . . . . . . . . . . . . . . . .
Cornelius Ice Makers Training Manual INTRODUCTION PREVIEW QUESTIONS Check your current knowledge by taking a few minutes to answer the following questions: 1. 2. 3. 4.
Cornelius Ice Makers Training Manual POPULAR APPLICATIONS Because of their unique form of ice and their extremely compact size, the Cornelius/Wilshire ice maker has a wide range of popular applications. The IMD model line has found wide acceptance in the convenience store market, where it provides a compact package with no need for the counter person to refill the ice bin. The U.S.
Cornelius Ice Makers Training Manual OVERVIEW Ice Storage Bin Ice Chute Ice Dispensing Lever FIGURE 1 Product Description Wilshire Ice Makers are available as ice making dispensers, modular chunklet, and modular flaked ice makers. Wilshire Continuous Chunklet (WCC) and Wilshire Continuous Flake (WCF) ice makers come in three sizes determined by their evaporators inside diameter, (ID).
Cornelius Ice Makers Training Manual Dimensions and Capacities IMD Units available with A/C or W/C condensers, Lever or Push button dispense. (W. D. H) Inches Bin Storage IMD 300-15, 15 x 24 x 35 IMD 300-30, 18.625 x 27.5 x 35.75 IMD 302-30, 18.625 x 27.5 x 35.75 IMD 600-30, 18.625 x 27.5 x 35.75 IMD 600-30, 24 x 29 x 41 IMD 601-90, 24 x 29 x 41 13 lbs. 30 lbs. 30 lbs. 30 lbs. 90 lbs. 90 lbs. Capacity lbs./24 hrs.
Cornelius Ice Makers Training Manual KEY POINTS — IMD / WCC / WCF ICE MAKERS SUPERHEAT & SUCTION TEMPERATURE Cornelius/Wilshire IMD/WCC/WCF ice makers run at only 4° F superheat. For this reason they are equipped with non-adjustable expansion valves. Suction temperature should be in the 5 to 8 degree below zero temperature range, regardless of refrigerant type. EVAPORATOR SQUEALING Squealing noises coming from the evaporator always are accompanied by low production.
Cornelius Ice Makers Training Manual EVAPORATOR EFFICIENCY The evaporator on the Cornelius/Wilshire ice maker can be tested for efficiency in three easy ways. 1. 2. 3. Simply observe the ice coming out of the extruding head during production. As the auger rotates, an ice chunklet should pop out of each extruder slot on every rotation. Frost pattern testing of the evaporator. Open up the ice maker so that the auger/extruding head can be removed.
Cornelius Ice Makers Training Manual IMD Component Identification Agitator motor Bin control switch Insulated Ice storage bin Evaporator Motor Transmission overload manual reset motor Water level control assy.
Cornelius Ice Makers Training Manual IMD Major Component Detail Instructor must explain the function of each component. • Dispense Motor - 115 VAC • Dispense Solenoid • Dispense Button • Dispense Timer • Bin Switch • Low Water Safety Switch • Auger Motor Delay • Auger Motor • Compressor • Compressor Start Components - start capacitor, run capacitor, start relay • Front End Assembly WCC / WCF Component Identification Instructor must explain the function of each component.
Cornelius Ice Makers Training Manual Extruder & Evaporator The extruding head bushing is replacable. It is a special bushing that contains no lead, and needs to be pressed into the shaft. The thrust bearings will become worn and should be replaced annually or as needed. Auger Auger Nut Nylon & Delrin thrust bearings Extruding head Extruding head bushing FIGURE 4 The seal between the transmission and the evaporator should be replaced when necessary.
Cornelius Ice Makers Training Manual SYSTEM DETAILS WATER AND FILTRATION Water quality and proper filtration are important for all ice makers. The correct filter is key to obtaining the best performance from the equipment. Filters should be of the taste and odor variety only. Filters that contain scale inhibitors or phosphates will cause chunklet ice to stick together or “bridge” in the bin. This will result in agitator damage.
Cornelius Ice Makers Training Manual REFRIGERATION Refrigeration System Operation The WCC/WCF refrigeration system is a critical charge unit with very low superheat. Therefore, it is important to not hook up refrigeration gauges unless absolutely necessary. The system works by feeding refrigerant into the evaporator via a non-adjustable expansion valve. The valve is connected at the lower port of the evaporator.
Cornelius Ice Makers Training Manual WCC/WCF CONTROLS AND ELECTRICAL The WCC/WCF control circuit is a series circuit consisting of the following components: 1. 2. 3. 4. 5. 6. Bin Control — Electrical power is routed through the primary and the secondary bin controls. The primary bin control is thermostatic, while the secondary is a mechanical switch located in the dispense tray lid. The purpose of the secondary switch is to act as a backup in the event of a primary switch failure.
Cornelius Ice Makers Training Manual FIGURE 7. Wiring Diagram © 2003, IMI Cornelius Inc.
Cornelius Ice Makers Training Manual BLACK COMPRESSOR C S R BIN CONTROL SWITCH SERVICE SWITCH 1 2 5 HIGH PRES. CUTOUT SWITCH AUGER GEAR MOTOR AUX BIN CONTROL SWITCH RUN CAP. 115 VAC LOW WATER SAFETY SWITCH START CAP. WATER COOLED ONLY START RELAY 7 4 A FAN MOTOR B WHITE FIGURE 8. Schematic and Wiring Diagram WCC500-A, WCC500-W, WCC700-A, WCC700-W, WCF510-A, WCF510-W, & WCF710-W BLACK COMPRESSOR C S R BIN CONTROL SWITCH LOW WATER SAFETY SWITCH HIGH PRES.
Cornelius Ice Makers Training Manual BLACK C S R COMPRESSOR BIN CONTROL SWITCH LOW WATER SAFETY SWITCH HIGH PRES. CUTOUT SWITCH SERVICE SWITCH AUGER GEARMOTOR AUX BIN CONTROL SWITCH RUN CAP. 208/230 60 HZ. 1 2 5 START CAP. WATER COOLED ONLY START RELAY 7 A 4 FAN MOTOR B RED FIGURE 10.
Cornelius Ice Makers Training Manual IMD CONTROLS AND ELECTRICAL The IMD series control circuit contains most of the same components used on the WCC/WCF units. The following components are unique to certain IMD models.
Cornelius Ice Makers Training Manual FIGURE 12. Schematic IMD 300-30, IMD600-30, IMD 601-30, IMD600-90, & IMD 601-90 © 2003, IMI Cornelius Inc.
Cornelius Ice Makers Training Manual APPENDICES APPENDIX A — INSTALLATION INFORMATION Bin / Dispenser Compatibility For ice bins, merely matching up with the top adapter is all that is required. Check with the dispenser’s manufacturer before installing any ice maker onto a dispenser. The top adapter, special agitator blades or a bin liner might be required. Automatic agitation circuits should be deactivated with extruded ice. Site Requirements There must be proper circulation for intake and exhaust air.
Cornelius Ice Makers Training Manual APPENDIX B — EVOLUTION OF THE CHUNKLET / FLAKER DESIGN The Chunklet / Flaker Ice Maker line currently being manufactured by Cornelius in its Mason City, Ia. facility originated in the 1950’s as the Reynolds ice maker. The original unit was designed for use exclusively in the post mix vending machine industry. The ice maker has evolved considerably since without losing its original design benefits, compact size, and high output.
Cornelius Ice Makers Training Manual APPENDIX C — EVAPORATOR REPLACEMENT Procedure for WCC / WCF Ice Makers 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Disconnect the water and power supply from the ice maker being serviced. Remove the exterior panels, top, front and sides in that order. Attach a gauge manifold set to the system and recover the refrigerant charge. Follow the reclaiming manufacturers instructions for the correct procedure.
Cornelius Ice Makers Training Manual TROUBLESHOOTING Top reasons for gear motor overload. GEAR MOTOR OVERLOAD CONDITION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Cornelius Ice Makers Training Manual REVIEW DATE: ____________________________________________________________________ NAME: ___________________________________________________________________ LOCATION: ___________________________________________________________________ The following questions summarize important points in this training lesson. 1.
Cornelius Ice Makers Training Manual NOTES _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ ____________________________________
Cornelius Ice Makers Training Manual Publication Number: TP00967 - 24 - © 2003, IMI Cornelius Inc.
IMI Cornelius Inc. One Cornelius Place Anoka, MN 55303-1592 U.S.A.
