Cornelius XAC 1444 Service Training Manual
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Cornelius XAC 1444 Service Training Manual

Xtreme ice xac series; xwc series; xrc series;
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Service / Training Manual
Revision Date: October 17, 2005
Release Date: November 26, 2001
Publication Number: TP00952
Revision: F
www.cornelius.com
Distributed By:
Commercial Refrigeration Service, Inc.
WWW.CorneliusParts.COM
WWW.IceCubes.NET
(866) 423-6253
(623) 869-8881
for model numbers
beginning with
XAC, XWC, or XRC

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Summary of Contents for Cornelius XAC 1444

  • Page 1 XAC, XWC, or XRC Service / Training Manual Distributed By: Commercial Refrigeration Service, Inc. WWW.CorneliusParts.COM WWW.IceCubes.NET (866) 423-6253 (623) 869-8881 Revision Date: October 17, 2005 Release Date: November 26, 2001 Publication Number: TP00952 Revision: F www.cornelius.com...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Product Preview ......... . Preview Questions .
  • Page 4 Harvest Cycle ............Fan control .
  • Page 5 Possible Causes ........... Failed Water System Shutdown .

  • Page 6: Product Preview

    Xtreme Ice Training Manual PRODUCT PREVIEW 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? _____ Yes _____ No? 2. What is the recommended clearance for a air cooled machine? ________________________________________________________________________________ ____________________________ 3.

  • Page 7: Model And Serial Location

    Xtreme Ice Training Manual MODEL AND SERIAL LOCATION XTREME ICE MACHINE Condenser Discharge Air Deflector (as required)* Bin Adapter (as required)* Model/Serial Number Location FIGURE 1 *Bin adapters and condenser discharge air deflector may be equipped depending on your location or the size of the storage bin.
  • Page 8 Xtreme Ice Training Manual Model 322/330 322/330 522/530 522/530 522/530 UNIT Volts Phase Hertz No. Wires 2+Ground 2+Ground MIN. CIRCUIT Amps MAX. FUSE SIZE. Amps REFRIGERANT R404 R404 R404 R404 Type R404a R404a R404a R404a R404a Weight (oz) Weight (g) 3,827 1,134 4,820...
  • Page 9 Xtreme Ice Training Manual XAC 330 XAC 522 XAC 530 Model 1444 1444 1444 1844 1844 1844 UNIT Volts Phase Hertz No. Wires 2+Ground 2+Ground MIN. CIRCUIT Amps MAX. FUSE SIZE Amps REFRIGERANT R404 R404 R404 R404 R404 R404 R404 Type R404a R404a...

  • Page 10: General

    Xtreme Ice Training Manual GENERAL FREIGHT DAMAGE CLAIMS PROCEDURE The deliverer of your equipment (freight company, distributor or dealer) is responsible for loss or damage of your shipment. All claims must be filed with the deliverer of your equipment. Please follow the steps below to determine if your shipment is satisfactory or if a claim must be filed: 1.

  • Page 11: Installation Instructions

    Xtreme Ice Training Manual INSTALLATION INSTRUCTIONS Installation and start up of the equipment should be performed by the distributor or the dealer’s profes- sional staff. LOCATION OF EQUIPMENT For maximum performance the location should be away from heat sources such as ovens, direct sunlight, hot air discharge, etc.

  • Page 12: Dispenser Installation

    Xtreme Ice Training Manual DISPENSER INSTALLATION 1. Order the proper cuber/dispenser adaptor kit. This package include gasket material, a hold-down bracket, and bin stat kit (contact service provider for more information). 2. RTV applications (See Figure 3). If the ice bin is full, new ice will not be able to drop. Instead it blocks the evaporator curtain open and no additional ice is made.

  • Page 13: Plumbing Connections

    Xtreme Ice Training Manual PLUMBING CONNECTIONS 1. All plumbing lines and connections must conform to local and national plumbing codes. 2. Line shut-off valves must be located in supply water lines for cuber and condenser if product is wa- ter-cooled. Water supply to water-cooled condenser must include a stand-pipe to prevent “water hammer”.

  • Page 14: Preventative Maintenance Sequence

    Xtreme Ice Training Manual Preventative Maintenance Sequence The installation is not complete until you are sure the owner-operator understands the cuber operation and his or her responsibility of preventative maintenance. Does the owner-operator know: Location of electrical disconnect switch and water shut-off valves? How to start and/or shut down the product, clean and sanitize it? Bin full operation and reset operation of high pressure cutout (water-cooled and remote products and 500 series (Air Cooled)?

  • Page 15: Cleaning Procedures

    Xtreme Ice Training Manual CLEANING PROCEDURES Approved ice machine cleaners by brand names: S Calgon Nickel Safe (green color only) NOTE: Failure to use approved products will void the warranty. CAUTION: Ice machine cleaners are acidic-based chemicals. Before beginning any cleaning of the cuber, the ice in the storage bin or dispenser must be removed.

  • Page 16: Prep - Cleaning Procedure

    Xtreme Ice Training Manual PREP – CLEANING PROCEDURE Use ice machine cleaner on a coarse-surface cloth material (such as terry cloth) and wipe down the in- side wall of the evaporator area, the water pan, the water curtain and the plastic water deflector. If the water distributor tube has heavy scale build-up, remove and soak it in full-strength nickel safe ice ma- chine cleaner (or exchange the tube and clean the scaled tube at a later date) (See Figure 6).

  • Page 17: Sanitizing The Water System And The Evaporator

    Xtreme Ice Training Manual SANITIZING THE WATER SYSTEM AND THE EVAPORATOR NOTE: To be performed only after cleaning the ice machine: 1. Turn the power switch to “OFF”. 2. Add 1/4 ounce (7.08 g) sodium hypochlorite solution (common liquid laundry bleach) to the water pan.

  • Page 18: Operations

    Xtreme Ice Training Manual OPERATIONS CAUTION: WHEN REPLACING THIS BOARD, BE SURE THE DIP SWITCH SETTINGS ARE IN THE PROPER POSITION FOR YOUR UNIT. UNIT SELECTION 1. The unit selection dip switches tell the microprocessor the correct water level difference for harvest and the number of proximity switch circuits to monitor.

  • Page 19: Start Up Sequence (Primary)

    Xtreme Ice Training Manual START UP SEQUENCE (PRIMARY) 1. Check all connections. 2. Water pan must be empty at the start of the initial fill cycle. 3. Turn on the main power switch, the red LED will flash 6 times then remains on for 4 seconds. NOTE: If there is a very large slab of ice on the evaporator you will need to push the manual har- vest button to remove it.

  • Page 20: Prechill Cycle (1400'S And 1800'S)

    Xtreme Ice Training Manual PRECHILL CYCLE (1400’S AND 1800’S) 1. After the water fill cycle is complete, the water pump turns on. 2. When the water temperature reaches 40_F, the pump turns off. 3. After one minute, the pump comes back on. 4.

  • Page 21: Adjusting Bridge Thickness

    Xtreme Ice Training Manual ADJUSTING BRIDGE THICKNESS For optimum ice production and maximum cube separation, the ice connecting the individual cubes should be a minimum of 1/8I (.32cm.) thick (See Figure 9). When adjusting the ice thickness, the adjust Led is on the control board, it will be on for four seconds when it is at nominal voltage 2.4 to 2.5 VDC  2% (See Figure 8 for location of the J9 connector).
  • Page 22 Xtreme Ice Training Manual COMPRESSOR COMPRESSOR START COMPRESSOR CAPACITOR CAPACITOR CONTACTOR 25 mfd 370V 60 HZ 72–88 mfd 250V 60 HZ EXTERNAL COMPRESSOR OVERLOAD UNIT SWITCH POTENTIAL START RELAY MANUAL RESET HIGH PRESSURE CONTROL(W/C ONLY) WATER FILL 450 PSIG WATER DUMP VALVE (White Lead) CONDENSER...

  • Page 23: Led Indicators

    Xtreme Ice Training Manual LED INDICATORS The LEDs are board circuit indicators. If the LED in the functional board circuit is complete, check component. Example: Contactor does not energize and LED is “ON”, board circuit is OK. Check contactor, coil, leads, &...

  • Page 24: Harvest Mode

    Xtreme Ice Training Manual Curtain Open Yellow LED Right evaporator curtain open. Yellow LED Left evaporator curtain open. Prechill Mode Condenser Fan Green LED (on or off) Condenser fan cycles on and off depending upon condenser temperature. Compressor Green LED (on) Compressor contactor active compressor running.

  • Page 25: Harvest Button

    Xtreme Ice Training Manual HARVEST BUTTON The Harvest Button is located on the control board (See Figure 5 in the Cleaning Procedures chapter. Manual Harvest 1. At any time after secondary start up, the machine can be put into the harvest cycle by depressing the harvest button.

  • Page 26: Safety (Old Software)

    Xtreme Ice Training Manual SAFETY (OLD SOFTWARE) NOTE: Prior to S/N 63K0344BC050 for self–contained units and S/N 63M0351BC056 for remote units. SAFETY FEATURES 1. Water Fill Time Out 2. Maximum Freeze Time Out 3. Harvest Time Out 4. Bin Full Delay 5.

  • Page 27: Water Fill Time Out

    Xtreme Ice Training Manual WATER FILL TIME OUT 1. During the fill cycle if the water level does not reach the maximum level in 4 minutes the machine goes into a delay sequence. 2. After each delay, the machine restarts at the secondary start up. 3.

  • Page 28: Harvest Time Out

    Xtreme Ice Training Manual HARVEST TIME OUT 1. If the microprocessor does not recognize all proximity switch circuits opening 4 minutes after the hot gas valve opens during the harvest cycle, the machine enters a delay sequence. 2. After each delay, the machine restarts at the secondary start up. 3.

  • Page 29: Possible Causes

    Xtreme Ice Training Manual 7. During delay period, the DELAY LED flashes 1 times at 4 second intervals. 8. Once the machine reaches shut down, all outputs turn off. 9. At the shut down time, the ERROR LED flashes 1 times at 4 second intervals. 10.

  • Page 30: Safety (New Software)

    Xtreme Ice Training Manual SAFETY (NEW SOFTWARE) NOTE: After S/N 63K0344BC050 for self–contained units and S/N 63M0351BC056 for remote units. SAFETY FEATURES 1. Failed Freeze Shutdown 2. Failed Harvest Shutdown 3. Bin Full Delay 4. Low Condenser Temperature Warning 5. High Condenser Temperature Warning and Shutdown 6.

  • Page 31: Failed Freeze Time Out Shutdown

    Xtreme Ice Training Manual FAILED FREEZE TIME OUT SHUTDOWN 1. If the freeze time reaches 50 minutes before a harvest cycle is initiated, the machine goes into the harvest cycle. 2. After a successful harvest cycle, the machine goes into another water fill and freeze cycle. 3.

  • Page 32: High Condenser Temperature Warning And Shutdown

    Xtreme Ice Training Manual HIGH CONDENSER TEMPERATURE WARNING AND SHUTDOWN 1. If the condenser temperature rises above 160 F, the machine shuts down. 2. While shut down, the WARNING LED flashes 1 time at 4–second intervals. 3. If the condenser temperature falls below 110 F, the machine goes into a secondary startup cycle.

  • Page 33: Failed Water Temperature Shutdown

    Xtreme Ice Training Manual FAILED WATER TEMPERATURE SHUTDOWN 1. If the water temperature does not reach 40 F within 5.5 minutes, the machine shuts down. 2. While shut down, the ERROR LED flashes 4 times at 4 second intervals. 3. The machine will not run until the power is cycled OFF and then ON. Possible Causes 1.

  • Page 34: Component Function (Circuit Board, Etc.)

    Xtreme Ice Training Manual COMPONENT FUNCTION (CIRCUIT BOARD, ETC.) SENSORS Condenser sensor (WHITE) is a thermistor rated at 2618 ohms to 3032 ohms at 32_F (0_C). Condenser sensor signals the circuit board for fan cycling and also serves as the high temperature safety shut down.

  • Page 35: Condenser Fan Cycling Control

    5. Poor water flow over evaporator 6. Ventilation problems The expansion valves used on Cornelius “X” series ice equipment have special super heat settings and bulb charge designed for the product load and HP 62 refrigerant. Should the need arise to replace this or any refrigerant components, be certain to use only components recommended by Cornelius for the model of the Cuber being serviced.

  • Page 36: Water Regulating Valve

    Xtreme Ice Training Manual WATER REGULATING VALVE The water regulating valve is used on water-cooled cubers only. The valve is installed in the condenser outlet water line. It’s function is to control the proper operating head pressure by regulating the amount of water flowing through the condenser.

  • Page 37: Moisture Contamination

    Xtreme Ice Training Manual MOISTURE CONTAMINATION With the major changes in refrigerants in today’s marketplace and the use of hydroscopic oils the control of moisture and contaminates have become more critical to safeguard against than ever before in the history of mechanical refrigeration. Contaminates are also the most difficult of all problems to determine.

  • Page 38: Compressor & Starting Component Check-Out Procedure

    Xtreme Ice Training Manual COMPRESSOR & STARTING COMPONENT CHECK-OUT PROCEDURE When a compressor fails to start or run properly, it is normally the external electrical supply or the com- pressor start components that are defective – the overload protector, start and/or run capacitor, relay, circuit board, safety controls, etc.

  • Page 39: Compressor

    Xtreme Ice Training Manual Compressor 1. Using an ohm meter, check for continuity from compressor terminal C to R and C to S. If the com- pressor is hot, wait one (1) hour for compressor to cool and recheck. An open internal overload pro- tector can cause a lack of continuity.

  • Page 40: System Evacuation & Recharging

    Xtreme Ice Training Manual SYSTEM EVACUATION & RECHARGING Should service work ever be required on a product where the sealed refrigeration is opened for any rea- son, the refrigerant must be recovered, drier/filter replaced, evacuated and recharged. The old method of “purging”...

  • Page 41: Refrigerant Definitions (Ashrae 3-1990)

    Xtreme Ice Training Manual IMPORTANT: Service personnel are held responsible for all aspects of the clean air act of July, 1992. REFRIGERANT DEFINITIONS (ASHRAE 3-1990) RECOVERY To remove refrigerant in any condition from a system and store it in an external container without neces- sarily testing or processing it in any way.

  • Page 42: Troubleshooting

    Xtreme Ice Training Manual TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. Trouble Probable Cause Remedy CUBER NOT OPERATING Power switch in “OFF” Place switch in “ON” position. position. CUBER NOT OPERATING, Test power switch and leads. If defective, replace.
  • Page 43 Xtreme Ice Training Manual Trouble Probable Cause Remedy COMPRESSOR RUNS BUT Low charge. Leak check – Recharge. DOES NOT COOL, CIRCUIT BOARD INDICATOR LIGHTS “ON” Hot gas solenoid leaking. Replace. Defective expansion valve. Replace. Inefficient compressor. Replace. Internal by-pass open, Permit pressures to equalize.
  • Page 44 Xtreme Ice Training Manual Trouble Probable Cause Remedy LONG HARVEST CYCLES Ice weight set too light. Adjust bridge per adjustment instructions. Unit not level. Level the unit. Water curtain movement Remove restriction. restricted. Low head pressure: ambient Minimum ambient temperature too low.
  • Page 45 Xtreme Ice Training Manual Trouble Probable Cause Remedy LEAKING WATER PAN Damaged water pan. Replace water pan (see Kit Instructions, number below, for Water Pan Replacement). Model # Kit # 631500152 500/600/800/1000 631500153 1200 631500154 Pull tab toward you. Turn pump clockwise and lift. FIGURE 15 NOTE: Remove pump tubing from the dump solenoid, after the pump has been lifted out of the res- ervoir, disconnect the distributor tubing at the tee fitting and lift pump out.
  • Page 46 Xtreme Ice Training Manual FIGURE 16 October 17, 2005 TP00952...
  • Page 47 Xtreme Ice Training Manual FIGURE 17 October 17, 2005 TP00952...

  • Page 48: Xtreme Ice - Kits

    Xtreme Ice Training Manual XTREME ICE – KITS BIN STAT KIT, P/N 630000408 Installation Instructions These Bin Stat kits apply to all “X” Series Ice makers. Loose–Shipped Parts Item No. Part No. Name Qty. 630000837 Thermostat Asy 07578 Screw TC 08–32 630460162 Installation Instruction, Thermostat 630900895...
  • Page 49 Xtreme Ice Training Manual ELECTRICAL BOX ASY TO CIRCUIT BOARD THERMOSTAT KIT ASY SCREW TC 08–32 631500074 COIL TO CHASSIS BASE FIGURE 18 October 17, 2005 TP00952...
  • Page 50 Xtreme Ice Training Manual (White Lead) Condenser Sensor See note 1 DELAY PRESSURE Transducer CLEAN ERROR Harvest Bridge Thickness Unit pot. Selection Switch Micro Valve FILL VALVE Processor (Manufacturing Date) 36430001 S3–1 DUMP VALVE S3–2 Dump FAN MOTOR (AIR COOLED) COMPRESSOR Comp WATER PUMP...
  • Page 51 Xtreme Ice Training Manual DETAIL SCALE 1:2 BIN STAT SUPPORT INSERT COIL AROUND 8–32 HEX BIN STAT SUPPORT CAPILLARY TUBE SEE DETAIL BIN STAT SUPPORT FIGURE 20 October 17, 2005 TP00952...

  • Page 52: Remote Condensers

    Xtreme Ice Training Manual REMOTE CONDENSERS Installation Instructions 1/4-20 SCREW UNIT BRACE FIGURE 21 1. Follow the standard installation instructions supplied with cuber. Do not hook cuber into the power source until the remote condenser and line set installation is complete. 2.
  • Page 53 The condenser fan may cycle off during the harvest cycle – this would be normal. NOTE: Installing an IMI Cornelius remote cuber with other than an IMI Cornelius remote condens- er and line set may be reason to void the cuber warranty.

  • Page 54: Remote Condenser Location

    To prevent the combination of rises, drops and horizontal runs exceeding the compressor start-up and pumping design limit, the following calculations should be made: NOTE: Max. line–set for IMI Cornelius cubers is 55 ft. Do not confuse line length with calculated line distance B - LINE LENGTH 35 FT.: EXAMPLE...
  • Page 55 Xtreme Ice Training Manual Insert measured drop (D) into formula and multiply by 6.6 to get a calculated drop (See Figure 26). example: A condenser located 8 ft. [2.438 meters] below the ice machine has a 52.8 ft. [16.093 meters] calculated total (8 ft. x 6.6 = 52.8 ft.). COMBINATION OF DROP(S) WITH HORIZONTAL...

  • Page 56: Head Pressure Control [Headmaster]

    70°F by-pass FIGURE 29 The Cornelius series remote systems use an Alco Head Pressure Control, normally referred to as a headmaster. This control is mounted in the remote condenser with a fan cycling control switch. Using both these controls gives the system positive operation under a wide range of condensing temperatures.

  • Page 57: Remote System Evacuation/Re-Charge

    Xtreme Ice Training Manual The headmaster controls the operation when the condensing temperature drops below 70°F. The refriger- ant charge is HP - 62 [R - 404A] and the headmaster dome charge setting is 200 PSI of nitrogen pres- sure making it stable under the low temperature operating range down to - 20°F. The normal flow pattern through the headmaster is from the condenser port to the receiver port.
  • Page 58 Xtreme Ice Training Manual 6. Always leak check entire system after recharge. CAUTION: Before programming the electronic scales to “dump” the charge, de-energize the liquid line solenoid, close the shut-off valve on vacuum pump and low side of the manifold set. 2ND STAGE CHARGING 1ST STAGE CHARGING EVACUATION...
  • Page 59 Xtreme Ice Training Manual THIS PAGE LEFT BLANK INTENTIONALLY October 17, 2005 TP00952...
  • Page 60 Xtreme Ice Training Manual Distributed By: Commercial Refrigeration Service, Inc. WWW.CorneliusParts.COM WWW.IceCubes.NET (866) 423-6253 (623) 869-8881 IMI CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota 55303-6234 (763) 421-6120 (800) 238-3600 October 17, 2005 TP00952...

This manual is also suitable for:

Xwc 1444Xac 1844Xwc 1844Xrc 1444Xrc 1844Xac 322 e50 ... Show all

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