I-SERIES ICE MACHINE TRAINING MANUAL Distributed By: Commercial Refrigeration Service, Inc. IOXIDE WWW.IceCubes.NET WWW.CorneliusParts.
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I-Series Ice Machine Training Manual I-Series Ice Machine 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.
I-Series Ice Machine Training Manual NOTES: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ ___________________________________
TABLE OF CONTENTS TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Preview Questions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 Key Things To Know / Do - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4 Overview - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
TABLE OF CONTENTS I-Series Ice Machine Training Manual Harvest Safety Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Stacking Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Ice Bridge Thickness Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Condenser Fan Cycling Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 Sensor - - - - - - - - - - - - - - - - - - - - - - - -
I-Series Ice Machine Training Manual INTRODUCTION 1. PREVIEW QUESTIONS Check your current knowledge by taking a few minutes to answer the following questions: 1. Does the ice machine need to be level? _____ No? 2. What is the recomended clearance for a air cooled machine? ____________________ ____________________________________________________________________ ____________________________________________________________________ 3.
I-Series Ice Machine Training Manual 2. KEY THINGS TO KNOW / DO INTRODUCTION • The sealant should be added before the unit is placed on the dispenser on bin. Always seal the ice maker to the bin (with a gasket or food grade sealant).
I-Series Ice Machine Training Manual 3. OVERVIEW Ice Machine ON/OFF/CLEAN and DUMP switches INTRODUCTION Ice Bin 3.1 Product Description The normal sequence of events for starting the I-Series Ice Machine is as follows: 1. The ON-OFF-CLEAN switch is switched ON. 2. Controller board does a startup check. 3. After 4 seconds the contactor closes and the compressor starts. 4. When the condenser thermistor reaches 100° F (38° C), the fan starts. The fan stops when the thermistor drops to 88° F (31° C). 5.
I-Series Ice Machine Training Manual 6. Ice builds on the evaporator to about 1/8” (.32cm) bridge thickness (center measure, adjustable). When the hot-gas defrost valve opens, the water dump valve opens, and the pump motor runs for 15 seconds to expel the waste water. INTRODUCTION NOTE: The hot-gas defrost valve opens at approximately 0° F (-18° C), and can be adjusted by turning the ice thickness potentiometer. Top row 3/8 - 5/8” (.95 - 1.59 cm) dimple Ice slab Center 1/8”(.
I-Series Ice Machine Training Manual SYSTEM DETAILS 1. CARBON DIOXIDE/AIR Not applicable for this product. 2. WATER + NOTE: Water related issues are the cause of the majority of ice maker problems. NOTE: Always use the proper type and size of water filter Inlet pressure should be 20 to 50 psi (1.4-3.45 BAR) at the ice machine. Water strainer Water goes first to a strainer. The strainer screen should be removed and cleaned at least once per year.
I-Series Ice Machine Training Manual 2.1 Dump Valve It is important to make sure that the dump valve is functioning properly. This valve dumps mineral laden water out the dump hose. The ice may become mushy if the valve does not open properly. If the valve sticks open, it will cause a longer freeze cycle. 1. Remove wire harness from the solenoid coil. Cap Coil Wire harness Dump hose 2. Remove blue cap and lift coil off. 3. Check coil resistance. It should be 140 ohms ± 10%. 4.
I-Series Ice Machine Training Manual NOTE: A bin thermostat is recommended for dispenser applications. When the bin thermostat is satisfied, the ice maker will finish the cycle it is in and shutdown. Part No. bin stat 630000-413 5. REFRIGERATION 5.1 Air Cooled Condensers Air cooled ice machines add heat to the surrounding environment. In some situations this may over tax the air conditioning system or cause other problems. Adequate air flow is necessary, including 6 inches (15.
I-Series Ice Machine Training Manual Use separate lines for the bin drain and the dump valve drain. It is usually not necessary to filter incoming condenser water. Follow standard procedures for cleaning condenser lines of scale and deposits. Water Regulating Valve The water regulating valve is used on water-cooled ice machines only. The valve is installed in the condenser outlet water line.
I-Series Ice Machine Training Manual 5.3 Remote Cooled Ice Machines Refer to I Series Ice Cube Machine Service Manual & Maintenance Guide for remote condenser installation information and correct refrigeration procedures. NOTE: When installing a remote ice maker, always open the receiver valve after connecting refrigerant lines. 5.4 Refrigeration System Expansion Valve The expansion valve is factory set at 6° F (-14° C) superheat (difference between evaporator inlet and outlet). It is non-adjustable.
I-Series Ice Machine Training Manual NOTE: Never judge the thickness of the ice from the first batch of the ice produced — the first cycle is a balance cycle. Always wait for the second cycle before making any adjustments. Refrigerant Charge/Recharge The refrigeration system is critically charged to within ± 1/2 ounces (14.8 ml), and does not use an accumulator. DO NOT use gauges until all other tests have been performed.
I-Series Ice Machine Training Manual Compressor Start Windings Check the compressor start windings. 1. With the power disconnected use an ohm meter to check each pair of terminals. There should NOT be an open circuit. 2. Take an amp reading from the red wire during defrost mode. The amps should match those on the name plate. Low amps indicate low refrigerant. Terminals Red wire 3. Check the voltage at the compressor terminals while the compressor is trying to start.
I-Series Ice Machine Training Manual The head pressure control valve (headmaster) maintains adequate condensing pressure during periods of low ambient temperature. The I-Series ice makers are charged with R404A refrigerant. The headmaster valve is set to maintain a condensing pressure of 200 psig (13.8 BAR) down to an operating temperature of -20°F (-6.7° C). SYSTEM DETAILS Touching the lines of the headmaster will determine the flow path the headmaster is in; condenser to receive, or bypass to receiver.
I-Series Ice Machine Training Manual 5.5 Suction Line Thermistor Replacement NOTE: The following procedure may be the easiest, but, it is not the only way replace the thermistor. 1. Unplug the ice machine and remove the top and front panels. 2. Remove plastic rivets from the electrical box mounting bracket using a punch and side cutters. Save the rivets for reinstallation. Punch thru center of rivet Side cutters to lift rivets Do Not Cut Remove 2 screws Remove 4 screws 3.
I-Series Ice Machine Training Manual 6. Reassemble, making sure the new thermistor is in the proper location. Replace the insulation around the thermistor or the ice machine will not function properly. 6. CONTROLS AND ELECTRICAL 6.
I-Series Ice Machine Training Manual TROUBLE SHOOTING 1. ISSUES AFFECTING ALL CIRCUIT BOARDS 1.1 Reset Operation When ice machine is shutdown and Error-LED is operational, the ice machine power switch must be turned OFF for approximately 5 seconds and returned to the ON position to reset the circuit board and allow the ice machine to restart operation. 1.2 Evaporator Proximity Switches Proximity switches are mounted to the evaporator and the magnet is mounted to water curtain.
I-Series Ice Machine Training Manual 2. Thicker Bridge - turn the ice thickness POT adjusting screw counterclockwise one full turn. Allow two cycles before determining if additional adjustments are required. NOTE: Never judge the thickness of the ice from the first batch of the ice produced — the first cycle is a balance cycle. Always wait for the second cycle before making any adjustments. 1.6 Condenser Fan Cycling Control The condenser fan on air cooled ice machines is cycled by the circuit board.
I-Series Ice Machine Training Manual 2. CIRCUIT BOARD OVERVIEW (RED & YELLOW BOARDS) 115V #7 YL Water Pump #6 BK Condenser Fan #5 BL P.S. #4 BL #3 RD Hot Gas #2 WH L2 #1 BR L1 230V #7 YL Water Pump #6 BK Condenser Fan #5 BL P.S. #4 BL #3 RD Hot Gas #2 RD L2 #1 BR L1 #7 YL Water Pump One Curtain Switch Must Be the second can be connected J5 SW4-1 OFF SW4-2 ON SW4-3 ON SERVICE © 2001, IMI Cornelius Inc.
I-Series Ice Machine Training Manual 2.
I-Series Ice Machine Training Manual D14 Green LED ON 15 seconds D15 Green LED ON D16 Green LED ON 15 seconds Water pump active for 15 sec., then inactive Compressor contactor closed (compressor active) Dump valve active 15 sec. Error-LEDs D9 Red LED D9 Red LED Turns on when the system is shutdown ON or flashing Assists to indicate where the error may be and or what may have caused the error D9 Red LED ON Evaporator temp.
I-Series Ice Machine Training Manual 3. RED & YELLOW BOARD DIAGNOSTICS With ice machine in freeze cycle, push and hold the Hot Gas Manual Harvest/Defrost Button until circuit board goes into diagnostic mode (about 3 seconds). The ice machine starts to cycle these five components: 1. Hot Gas Solenoid 2. Water Pump 3. Contactor 4. Fan Motor 5. Dump Valve. Check to make sure the proximity switch lights are on. When replacing the circuit board make sure the dip switches are set correctly.
I-Series Ice Machine Training Manual 3.1 Sensors The suction line sensor (blue) is a thermistor rated at 2815 ohm ± 5%, at 32° F (0° C). This sensor controls the ice bridge thickness by measuring the suction line temperature and sending it to the circuit board. The circuit board controls the compressor. If the suction line temperature does not drop to 40° F (4.4° C) in 6 minutes, the ice machine goes into a safety shutdown mode. A manual reset must be performed. 3.2 Check Circuit Board Output 1.
I-Series Ice Machine Training Manual 4. GREEN CIRCUIT BOARD OVERVIEW 4.1 GREEN BOARD Test Plug SERVICE This plug is primarily for the manufacture’s use. - 24 - © 2001, IMI Cornelius Inc.
I-Series Ice Machine Training Manual 4.2 GREEN BOARD Sensors Condenser sensor and suction line sensor are thermistors rated at 2815 ohms ± 5% at 32° F (0° C). Condenser Sensor signals the circuit board for fan cycling, and serves as the hightemperature safety shutdown. The Error-LED will flash once a second during high temperature safety shutdown. Manual reset must be performed to restart “ON” at 100°F, “OFF” at 88°F Suction Line Sensor signals the circuit board about the suction line temperature.
I-Series Ice Machine Training Manual 6. As the suction line temperature decreases the milli-volt reading should increase. • If the multimeter reading remains steady and does not increase, it indicates a shorted sensor. Replace the sensor and check again. • If the multimeter reading is 2.5 VDC it indicates an open sensor. Replace the sensor and check again. 4.5 Sensors The suction line sensor is a thermistor rated at 2815 ohm ± 5%, at 32° F (0° C).
I-Series Ice Machine Training Manual 4.8 GREEN BOARD Dump Cycle Options SERVICE © 2001, IMI Cornelius Inc.
I-Series Ice Machine Training Manual 4.9 GREEN BOARD Diagnostics Erratic Component Operation Erratic component operation (water pump, condenser fan, hot gas valve, etc.) are often the result of a poor connection to the 8-pin connector. Before performing diagnostics on the circuit board, make sure the 8-pin connector is securely in place. Check Circuit Board 1. Turn the power switch ON. The D-5 Error-LED indicator will be illuminated for 2 seconds. 2.
I-Series Ice Machine Training Manual APPENDIX APPENDIX APPENDIX A — SERVICE TIPS • Use nickel safe cleaner when cleaning evaporators. • Use only Cornelius parts in servicing ice makers. APPENDIX B — INSTALLATION TIPS • Purge water lines. • Level the ice machine. • Seal the ice maker to the bin or dispenser. • Use a dedicated electrical circuit with proper sized wire and breaker. • Provide adequate clearance. • Fasten the ice maker to the bin or adapter. © 2001, IMI Cornelius Inc.
I-Series Ice Machine Training Manual REVIEW DATE: _______________________________________________ NAME: _______________________________________________ REVIEW LOCATION: __________________________________________ General Ice Maker Installation The following questions summarize important points in this training lesson 1. What is the minimum and maximum ambient temperatures for a ice maker installation. ___A. 25° F to 60° F ___B. 50° F to 100° F ___C. 72° F ±10° F ___D.
Ice Cuber Operation 5. What refrigerant is used in the “I” series cube ice maker ___A. R404a ___B. R22 ___C. R12 ___D. HP62 6. On a air cooled cuber, thermistors are located at the following locations: ___A. Evaporator, condenser, and suction line. ___B. Condenser and suction line. ___C. Dump valve, hot gas valve, and evaporator. 7. The thermostatic expansion valve is ___A. Nonadjustable. ___B. Internally adjustable. ___C. Externally adjustable. ___D. automatically adjustable. 8.
11. When the evaporator curtain is moved away from the evaporator ___A. The machine will return to the freeze cycle if the bin is not full. ___B. The machine will shut down. ___C. A malfunction of the curtain is indicated and it must be replaced. ___D. Both A and B. 12. When the machine enters the defrost cycle, which components are energized? ___A. Compressor, condenser fan, and the hot gas solenoid. ___B. Hot gas solenoid and the dump valve only. ___C. Only the hot gas solenoid. ___D.
I-Series Ice Machine Training Manual 18. When the cuber is shut down and the red LED is illuminated, to reset ___A. Push the reset button. ___B. Close the proximity switch. ___C. Turn the power switch off at least 5 seconds. ___D. The board automatically resets after 2 minutes. 19. To test the board for proper proximity switch operation, the voltage reading across the switch terminal is ___A. 2.5VDC ___B. 2.5VAC ___C. 5VDC ___D. 5VAC © 2001, IMI Cornelius Inc.
- 34 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2062 1862 1841 1572 1379 47 45 44 42 39 SUCTION PRESSURE Psig 324 310 303 290 269 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 299 270 267 228 200 HEAD PRESSURE Psig FREEZE CYCLE 19:8 15:1 14:3 12:4 9:5 CYCLE TIME Min:Sec 19:8 15:1 14:3 12:4 9:5 CYCLE TIME Min:Sec 142 130 133 110 105 SUCTION PRES
© 2001, IMI Cornelius Inc.
- 36 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2206 1999 1896 1724 1517 46 45 41 42 38 SUCTION PRESSURE Psig 317 310 283 290 262 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 320 290 275 250 220 HEAD PRESSURE Psig FREEZE CYCLE 20:9 17:9 17:4 14:6 12:5 CYCLE TIME Min:Sec 20:9 17:9 17:4 14:6 12:5 CYCLE TIME Min:Sec 120 120 120 111 95 SUCTION PRE
© 2001, IMI Cornelius Inc.
- 38 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2296 2048 2041 1800 1551 43 40 40 37 34 SUCTION PRESSURE Psig 296 276 276 255 234 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 333 297 296 261 225 HEAD PRESSURE Psig FREEZE CYCLE 17:1 13:2 12:6 11:3 8:4 CYCLE TIME Min:Sec 17:1 13:2 12:6 11:3 8:4 CYCLE TIME Min:Sec 125 113 113 101 88 SUCTION PRESS
© 2001, IMI Cornelius Inc.
- 40 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2296 2048 2041 1800 1551 43 40 40 37 34 SUCTION PRESSURE Psig 296 276 276 255 234 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 333 297 296 261 225 HEAD PRESSURE Psig FREEZE CYCLE 17:1 13:2 12:6 11:3 8:4 CYCLE TIME Min:Sec 17:1 13:2 12:6 11:3 8:4 CYCLE TIME Min:Sec 125 113 113 101 88 SUCTION PRESS
© 2001, IMI Cornelius Inc.
- 42 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2034 2055 2034 2041 2055 34 37 34 34 32 SUCTION PRESSURE Psig 234 255 234 234 221 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 295 298 295 296 298 HEAD PRESSURE Psig FREEZE CYCLE 11:1 12:1 10:7 10:2 8:6 CYCLE TIME Min:Sec 11:1 12:1 10:7 10:2 8:6 CYCLE TIME Min:Sec 93 88 87 86 81 SUCTION PRESSURE
© 2001, IMI Cornelius Inc.
- 44 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2406 2158 2151 1903 1655 41 38 38 36 33 SUCTION PRESSURE Psig 283 262 262 248 228 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 349 313 312 276 240 HEAD PRESSURE Psig FREEZE CYCLE 18:7 16:8 15:9 14:2 13:5 CYCLE TIME Min:Sec 18:7 16:8 15:9 14:2 13:5 CYCLE TIME Min:Sec 100 91 91 83 75 SUCTION PRESSU
© 2001, IMI Cornelius Inc.
- 46 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2406 2158 2151 1903 1655 40 38 38 36 33 SUCTION PRESSURE Psig 283 262 262 248 228 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 349 313 312 276 240 HEAD PRESSURE Psig FREEZE CYCLE 18:7 16:8 15:9 14:2 13:5 CYCLE TIME Min:Sec 18:7 16:8 15:9 14:2 13:5 CYCLE TIME Min:Sec 100 91 91 83 75 SUCTION PRESSU
© 2001, IMI Cornelius Inc.
- 48 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2234 2227 2275 2234 2317 30 32 33 30 30 SUCTION PRESSURE Psig 207 221 228 207 207 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 324 323 330 324 336 HEAD PRESSURE Psig FREEZE CYCLE 14:0 14:8 14:0 13:2 10:1 CYCLE TIME Min:Sec 14:0 14:8 14:0 13:2 10:1 CYCLE TIME Min:Sec 76 78 76 76 73 SUCTION PRESSUR
© 2001, IMI Cornelius Inc.
- 50 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2427 2186 2172 1931 1696 38 37 35 34 31 SUCTION PRESSURE Psig 262 255 241 234 214 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 352 317 315 280 246 HEAD PRESSURE Psig FREEZE CYCLE 15:8 13:7 13:2 11:8 10:1 CYCLE TIME Min:Sec 15:8 13:7 13:2 11:8 10:1 CYCLE TIME Min:Sec 106 98 97 88 79 SUCTION PRESSU
© 2001, IMI Cornelius Inc.
- 52 50 70 70 80 70 70 80 90 90 100 27 21 32 38 21 27 21 10 21 32 WATER TEMP ° C AMBIENT TEMP° C SI Units WATER TEMP ° F AMBIENT TEMP° F IP Units 2427 2186 2172 1931 1696 38 37 35 34 31 SUCTION PRESSURE Psig 262 255 241 234 214 SUCTION PRESSURE kPa FREEZE CYCLE HEAD PRESSURE kPa 352 317 315 280 246 HEAD PRESSURE Psig FREEZE CYCLE 15:8 13:7 13:2 11:8 10:1 CYCLE TIME Min:Sec 15:8 13:7 13:2 11:8 10:1 CYCLE TIME Min:Sec 106 98 97 88 79 SUCTION PRESSU
I-Series Ice Machine Training Manual IMI Cornelius Inc. One Cornelius Place Anoka, MN 55303-6234 U.S.A. Part No. TP00919 May 8, 2001 © 2001, IMI Cornelius Inc.
I-Series Ice Machine Training Manual - 54 - © 2001, IMI Cornelius Inc.
