Cornelius I-SERIES Training Manual
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Cornelius I-SERIES Training Manual

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Download this manual See also: Use and Care Manual
I-S
I
ERIES
CE
T
RAINING
C
D
ARBON
IOXIDE
W
ATER
S
/C
YRUP
M
ECHANICAL
R
EFRIGERATION
C
ONTROLS
M
ACHINE
M
ANUAL
Commercial Refrigeration Service, Inc.
ONCENTRATE
& E
Distributed By:
WWW.IceCubes.NET
WWW.CorneliusParts.COM
(866) 423-6253
(623) 869-8881
LECTRICAL

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  • Page 1 ERIES ACHINE RAINING ANUAL Distributed By: Commercial Refrigeration Service, Inc. ARBON IOXIDE WWW.IceCubes.NET WWW.CorneliusParts.COM ATER (866) 423-6253 YRUP ONCENTRATE (623) 869-8881 ECHANICAL EFRIGERATION & E ONTROLS LECTRICAL...
  • Page 2 Blank Page Distributed By: Commercial Refrigeration Service, Inc. WWW.IceCubes.NET WWW.CorneliusParts.COM (866) 423-6253 (623) 869-8881...
  • Page 3 FAX: 800-535-4231 Trademarks and copyrights: Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olym- pus, and Vista are registered trademarks of IMI Cornelius Inc. Optifill trademark is pending. This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius.
  • Page 4 I-Series Ice Machine Training Manual NOTES: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________...

  • Page 5: Table Of Contents

    I-Series Ice Machine Training Manual TABLE OF CONTENTS TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1...
  • Page 6 I-Series Ice Machine Training Manual Harvest Safety Termination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17...

  • Page 7: Introduction

    I-Series Ice Machine Training Manual INTRODUCTION 1. P REVIEW UESTIONS 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 recomended clearance for a air cooled machine? ____________________...

  • Page 8: Key Things To Know / Do

    I-Series Ice Machine Training Manual 2. K HINGS • 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). Sealing prevents melted ice from running out the joint between the ice machines! •...

  • Page 9: Overview

    DUMP switches 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.

  • Page 10: Dimensions & Capacities

    I-Series Ice Machine Training Manual 6. Ice builds on the evaporator Top row to about 1/8” (.32cm) bridge 3/8 - 5/8” thickness (center measure, (.95 - 1.59 cm) dimple adjustable). When the hot-gas defrost valve opens, the water Ice slab...

  • Page 11: System Details

    I-Series Ice Machine Training Manual SYSTEM DETAILS 1. C ARBON IOXIDE Not applicable for this product. 2. W ATER 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...

  • Page 12: Dump Valve

    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. Coil The ice may become mushy if the valve does not Wire open properly.

  • Page 13: Refrigeration

    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 shut- down. Part No. bin stat 630000-413 5. R EFRIGERATION 5.1 Air Cooled Condensers...

  • Page 14: Water Regulating Valve

    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.

  • Page 15: Remote Cooled Ice Machines

    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.

  • Page 16: Refrigerant Charge/Recharge

    Then evacuate and recharge the system BY WEIGHT. NOTE: The R404A refrigerant used in the I-Series ice machines is a blend of several refrigerants. These can fractionate in the refrigeration system. This is why it is so important to completely evacuate the system before recharging.

  • Page 17: Compressor Start Windings

    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.
  • Page 18 I-Series Ice Machine Training Manual The head pressure control valve (headmaster) maintains adequate condensing pres- sure 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 pres- sure of 200 psig (13.8 BAR) down to an operating temperature of -20°F (-6.7°...

  • Page 19: Suction Line Thermistor Replacement

    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.

  • Page 20: Controls And Electrical

    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. C ONTROLS AND LECTRICAL 6.1 Controls Board Features (Red and Yellow Boards) •...

  • Page 21: Trouble Shooting

    1.4 Stacking Cable When two I-series ice machines are stacked, a cable is used to connect their circuit boards. This allows the bottom unit to be shut down on a Full Bin Signal (or other error code). The top unit will finish the cycle it is in, and shut down.

  • Page 22: Condenser Fan Cycling Control

    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 pro- duced —...

  • Page 23: Circuit Board Overview (Red & Yellow Boards)

    I-Series Ice Machine Training Manual 2. C & IRCUIT OARD VERVIEW YELLOW BOARDS 115V 230V #7 YL Water Pump #7 YL Water Pump #6 BK Condenser Fan #6 BK Condenser Fan #5 BL P.S. #5 BL P.S. #4 BL #4 BL...

  • Page 24: Red & Yellow Boards (Leds) Descriptions

    I-Series Ice Machine Training Manual 2.1 Red & Yellow Boards (LEDs) Descriptions Status Indicators Yellow Water curtain(s) dip switch can be set for 1, 2, or 4 D1-2 D3-4 evaporator machines Red LED Error Green LED Hot gas valve(s) Green LED...
  • Page 25 I-Series Ice Machine Training Manual ON 15 Green LED Water pump active for 15 sec., then inactive seconds Compressor contactor closed (compressor Green LED active) ON 15 Green LED Dump valve active 15 sec. seconds Error-LEDs Red LED Turns on when the system is shutdown...

  • Page 26: Red & Yellow Board Diagnostics

    I-Series Ice Machine Training Manual 3. R & Y ELLOW OARD IAGNOSTICS With ice machine in freeze cycle, push and hold the Hot Gas Manual Harvest/Defrost But- ton until circuit board goes into diagnostic mode (about 3 seconds). The ice machine starts to cycle these five components: 1.

  • Page 27: Check Circuit Board

    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.

  • Page 28: Green Circuit Board Overview

    I-Series Ice Machine Training Manual 4. G REEN IRCUIT OARD VERVIEW Test Plug REEN OARD This plug is primarily for the manufacture’s use. - 24 - © 2001, IMI Cornelius Inc.

  • Page 29: Green Board Sensors

    I-Series Ice Machine Training Manual Sensors REEN OARD 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 high- temperature safety shutdown.
  • Page 30 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.

  • Page 31: Green Board Dump Cycle Options

    I-Series Ice Machine Training Manual Dump Cycle Options REEN OARD - 27 - © 2001, IMI Cornelius Inc.

  • Page 32: Check Circuit Board

    I-Series Ice Machine Training Manual Diagnostics REEN OARD 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 diag- nostics on the circuit board, make sure the 8-pin connector is securely in place.

  • Page 33: Appendix

    I-Series Ice Machine Training Manual APPENDIX A — S PPENDIX ERVICE • Use nickel safe cleaner when cleaning evaporators. • Use only Cornelius parts in servicing ice makers. B — I PPENDIX NSTALLATION • Purge water lines. • Level the ice machine.

  • Page 34: Review

    I-Series Ice Machine Training Manual REVIEW DATE: _______________________________________________ NAME: _______________________________________________ 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.
  • Page 35 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.
  • Page 36 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.
  • Page 37 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.
  • Page 38 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IACS 227/IAC 322/IAC 330 - 34 - © 2001, IMI Cornelius Inc.
  • Page 39 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IWCS 227/IWC 322/IWC 330 - 35 - © 2001, IMI Cornelius Inc.
  • Page 40 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IAC 522/IAC 530 - 36 - © 2001, IMI Cornelius Inc.
  • Page 41 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IWC 522/IWC 530 - 37 - © 2001, IMI Cornelius Inc.
  • Page 42 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IAC 630 - 38 - © 2001, IMI Cornelius Inc.
  • Page 43 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IWC 630 - 39 - © 2001, IMI Cornelius Inc.
  • Page 44 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IRC 630 - 40 - © 2001, IMI Cornelius Inc.
  • Page 45 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IAC 830 - 41 - © 2001, IMI Cornelius Inc.
  • Page 46 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IWC 830 - 42 - © 2001, IMI Cornelius Inc.
  • Page 47 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IRC 830 - 43 - © 2001, IMI Cornelius Inc.
  • Page 48 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IAC 1030 - 44 - © 2001, IMI Cornelius Inc.
  • Page 49 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IWC 1030 - 45 - © 2001, IMI Cornelius Inc.
  • Page 50 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IRC 1030 - 46 - © 2001, IMI Cornelius Inc.
  • Page 51 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IAC 1230 - 47 - © 2001, IMI Cornelius Inc.
  • Page 52 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IWC 1230 - 48 - © 2001, IMI Cornelius Inc.
  • Page 53 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IRC 1230 - 49 - © 2001, IMI Cornelius Inc.
  • Page 54 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IAC 1448 - 50 - © 2001, IMI Cornelius Inc.
  • Page 55 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IWC 1448 - 51 - © 2001, IMI Cornelius Inc.
  • Page 56 I-Series Ice Machine Training Manual AVERAGE OPERATING CHARACTERISTICS IRC 1448 - 52 - © 2001, IMI Cornelius Inc.
  • Page 57 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 - 53 - © 2001, IMI Cornelius Inc.
  • Page 58 I-Series Ice Machine Training Manual - 54 - © 2001, IMI Cornelius Inc.

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