Cornelius 500 Series Installation And Service Manual
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Cornelius 500 Series Installation And Service Manual

Cornelius 500 Series Installation And Service Manual

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CONTINUOUS FLOW ICEMAKER
500 - 700 - 1000 - 2000 Series
Installation and Service Manual
Release Date: August 1, 2002
Publication Number: 638085278
Revision Date: March 19, 2014
Revision: F
Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

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  • Page 1 CONTINUOUS FLOW ICEMAKER 500 - 700 - 1000 - 2000 Series Installation and Service Manual Release Date: August 1, 2002 Publication Number: 638085278 Revision Date: March 19, 2014 Revision: F Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

  • Page 2: Contact Information

    Commercial Warranty. Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Safety Instructions ..............1 Read and Follow ALL Safety Instructions .
  • Page 4 Refrigeration and Icemaker Assembly Model 500 Series ....... . 30...

  • Page 5: Safety Instructions

    Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE. Publication Number: 638085278 - 1 - © 2002-2014, Cornelius Inc.

  • Page 6: Safety Precautions

    Failure to do so may cause damage to unit, which would void unit warranty. NOTE: Using any parts other than genuine factory manufactured parts relieves the manufacturer of all liability. NOTE: Manufacturer reserves the right to change specifications at any time. © 2002-2014, Cornelius Inc. - 2 - Publication Number: 638085278...

  • Page 7: General Description

    Water Cooled 208/230 12.9 (2) 2 R404A WCF2202-A Air Cooled 220/240 11.4 0.85 (2) 2 R404A NOTE: For units not listed in above chart, refer to nameplate or contact factory service. Publication Number: 638085278 - 3 - © 2002-2014, Cornelius Inc.
  • Page 8 Continuous Flow Icemaker Installation and Service Manual Temperature Charts Figure 1. Series 500 & 700 Dimension Drawing (Shipping Wt. Approx. 160 lbs.) © 2002-2014, Cornelius Inc. - 4 - Publication Number: 638085278...
  • Page 9 Continuous Flow Icemaker Installation and Service Manual Figure 2. Series 1000 Dimension Drawing (Shipping Wt. Approx. 120 lbs.) Publication Number: 638085278 - 5 - © 2002-2014, Cornelius Inc.
  • Page 10 Continuous Flow Icemaker Installation and Service Manual Figure 3. Series WCC2001-A and WCF2201-A Dimension Drawings © 2002-2014, Cornelius Inc. - 6 - Publication Number: 638085278...

  • Page 11: Installation

    1. Overflow Line—is a 3/8” I.D. flexible tube located at the rear of the unit. Extend this line to proper drain. 2. Condenser Outlet—is a 3/8” FPT located on the rear panel. NOTE: Unit must be installed per local plumbing code BOCA. Publication Number: 638085278 - 7 - © 2002-2014, Cornelius Inc.

  • Page 12: Electrical Supply

    Bin Control—Place ice around probe, unit should shut down in one minute. Remove ice from around probe, unit should start in two minutes. NOTE: For altitudes over 1000 feet above sea level, adjust range screw (behind end cover). Half ° turn max. raises setting 4 F approx. © 2002-2014, Cornelius Inc. - 8 - Publication Number: 638085278...
  • Page 13 NOTE: If any of these checks or adjustments cannot be achieved, refer to Troubleshooting Section of this manual or call for factory assistance at 1-800-Service. Figure 6. Schematic and Wiring Diagram WCC2001-A and WCF2201-A Publication Number: 638085278 - 9 - © 2002-2014, Cornelius Inc.
  • Page 14 Figure 7. Schematic and Wiring Diagram for WC500-A, WCC 500-W, WCC700-A, WCC700-W, WCF510-A, WCF510-W, WCF710-A and WCF710-W Figure 8. Schematic and Wiring Diagram for WCC701-A, WCC701-W, WCF1001-A, WCF1001-W, WCF711-A, WCF711-W, WCF1101-A and WCF1101-W © 2002-2014, Cornelius Inc. - 10 - Publication Number: 638085278...
  • Page 15 Continuous Flow Icemaker Installation and Service Manual Schematic and Wiring Diagram WCF1101R, WCC1001R, WCF1102R, & WCC1102R Figure 9. Figure 10. Schematic and Wiring Diagram WCC502, WCC702, WCC1002, WCF512, WCF712, & WCF1102 Publication Number: 638085278 - 11 - © 2002-2014, Cornelius Inc.
  • Page 16 Continuous Flow Icemaker Installation and Service Manual Figure 11. Schematic and Wiring Diagram WCC2001-R and WCF2201-R © 2002-2014, Cornelius Inc. - 12 - Publication Number: 638085278...

  • Page 17: Guide To Service

    This is the maximum period of time between cleaning and sanitizing the icemaker. In addition to recommended monthly procedure, and if a more frequent cleaning and sanitizing pattern has not been established, unit must be cleaned and sanitized. Publication Number: 638085278 - 13 - © 2002-2014, Cornelius Inc.

  • Page 18: Semi-Annually

    6. Check unit for abnormal noise. Tighten machine and cabinet screws, if necessary. 7. Check white upper bearings on auger assembly. If bearings are less than 1/16” thick, replace. See Figure 12. Figure 12. Upper Nut and Bearing Assembly © 2002-2014, Cornelius Inc. - 14 - Publication Number: 638085278...

  • Page 19: Water Level Control

    2. Unplug molex connector connecting switch to electrical box. 3. Remove the two (2) screws anchoring the water level safety switch to the bottom of the water level control mounting bracket. Publication Number: 638085278 - 15 - © 2002-2014, Cornelius Inc.

  • Page 20: Refrigeration System

    NOTE: Units with thermostatic expansion valve-valve is located on bottom refrigerant line. Sensing bulb is located on top refrigerant line. On water cooled units adjust condenser modulating valve before troubleshooting expansion valve. © 2002-2014, Cornelius Inc. - 16 - Publication Number: 638085278...

  • Page 21: Condenser Modulating Valve

    NOTE: Cold water will absorb heat faster than warm water. The water flow will therefore automatically increase as inlet temperature increases. Figure 13. Expansion Valve Figure 14. Adjustment Screw Publication Number: 638085278 - 17 - © 2002-2014, Cornelius Inc.

  • Page 22: Condenser Modulating Valve Removal

    This icemaker is also equipped with a safety ice level sensor. This sensor control is located on the dispense tray cover. This switch is also in series with the anti-freeze relay and other safety circuitry. Figure 15. Bin Control Switch © 2002-2014, Cornelius Inc. - 18 - Publication Number: 638085278...

  • Page 23: Gear Motor

    If the motor is subjected to an abnormal load, but does not reach a stall condition, the overload will react, but over a greater period of time. The reaction time depends upon the amperage to which it is subjected. The overload, through the safety circuit, also shuts off the compressor. Publication Number: 638085278 - 19 - © 2002-2014, Cornelius Inc.

  • Page 24: Motor Check

    Remove the transmission from the unit. 4. When replacing the transmission, it may be necessary to rotate the auger back and forth to align the motor shaft and auger. © 2002-2014, Cornelius Inc. - 20 - Publication Number: 638085278...

  • Page 25: Installation And Shaft Seal Replacement 500

    4. When replacing the auger assembly, make certain that both the auger engages the output shaft drive and the extruding head ribs engage the evaporator tube. (See Figure 18) Publication Number: 638085278 - 21 - © 2002-2014, Cornelius Inc.

  • Page 26: Installation And Shaft Seal Replacement 700 & 1000

    3. Use an open end wrench on the auger nut connected to the bearing and turn counterclockwise to remove the assembly. 4. Remove worn bearings. Replace them with new bearings and then reinstall assembly. © 2002-2014, Cornelius Inc. - 22 - Publication Number: 638085278...

  • Page 27: Electrical Checkout

    4. Check between screw terminal on the overload and “C” on the compressor. Check and repair the lead or con- nections if there is no continuity. Publication Number: 638085278 - 23 - © 2002-2014, Cornelius Inc.

  • Page 28: Capacitor Check

    4. Anti-freeze relay and associated circuit. (See wiring diagrams, Figure 7, Figure 8, Figure 9 and Figure 10.) 5. Main service switch located on top of the control box. (See Figure 15.) 6. Bin Control (See Figure 15.) 7. High pressure cut out (water cooled only.) © 2002-2014, Cornelius Inc. - 24 - Publication Number: 638085278...

  • Page 29: Guide To Good Ice

    Continuous Flow Icemaker Installation and Service Manual GUIDE TO GOOD ICE Publication Number: 638085278 - 25 - © 2002-2014, Cornelius Inc.
  • Page 30 Continuous Flow Icemaker Installation and Service Manual © 2002-2014, Cornelius Inc. - 26 - Publication Number: 638085278...

  • Page 31: Troubleshooting

    It should never exceed 120% of the rated nameplate amperage. See electrical checkout instructions. The compressor runs but does not Compressor not working Check the compressor suctions refrigerate and discharge pressures. See chart on page 15. Publication Number: 638085278 - 27 - © 2002-2014, Cornelius Inc.

  • Page 32: Parts List

    High Pressure Switch (Water) (Not Shown) 161773003 Pressure Switch (WCC and WCF Remote) (Not Shown) 166226000 Valve Head Pressure (WCC and WCF Remote) (Not Shown) 166225000 Receiver (WCC and WCF Remote) (Not Shown) © 2002-2014, Cornelius Inc. - 28 - Publication Number: 638085278...
  • Page 33 Continuous Flow Icemaker Installation and Service Manual Figure 25. Refrigeration and Icemaker Assembly Model 500 Series Publication Number: 638085278 - 29 - © 2002-2014, Cornelius Inc.

  • Page 34: Refrigeration And Icemaker Assembly Model 500 Series

    Capacitor Start 115V 638036218 Bracket, Mounting Icemaker 638090134 Capacitor Start 220V 50Hz 638008409 Bulkhead Fitting 638090123 Capacitor Run 115V 638007206-04 Nut, Jam 1/2-20 638036267 Fan Shroud 638004393 Dryer NOTE: * Not Shown © 2002-2014, Cornelius Inc. - 30 - Publication Number: 638085278...
  • Page 35 Continuous Flow Icemaker Installation and Service Manual Figure 27. Refrigeration and Icemaker Assembly Model 700 Series Publication Number: 638085278 - 31 - © 2002-2014, Cornelius Inc.

  • Page 36: Refrigeration And Icemaker Assembly Model 700 Series

    Bracket, Mounting Icemaker 638008409 Bulkhead Fitting NOTE: * = Not Shown. 638007206-04 Nut, Jam 1/2-20 638004393 Dryer 638036865 Cover and Detector Assembly - Dispense Tray 638036883 Cover, Dispense Tray 638036867-001 Clip Cover © 2002-2014, Cornelius Inc. - 32 - Publication Number: 638085278...
  • Page 37 Continuous Flow Icemaker Installation and Service Manual Figure 28. Refrigeration and Icemaker Assembly Model 1000 Series Publication Number: 638085278 - 33 - © 2002-2014, Cornelius Inc.

  • Page 38: Refrigeration And Icemaker Assembly Model 1000 Series

    638037110 Washer, Seal 638090344-002 Fan Motor Assembly, 220V 50Hz 638037111 Valve, Rotolock 638036011 Fan Blade 638036014 Cover, Electrical Box 638004391 Bracket, Fan Motor 638090349 Bracket, Mounting NOTE: * Not Shown. © 2002-2014, Cornelius Inc. - 34 - Publication Number: 638085278...
  • Page 39 Bracket Water Level WCC2000 638007217 Nut 1-14 WCC1000/2000 638008097 Clamp, Reed Switch 638030823 Hardware, Water Level Control 638007002-01 Screw Valve Body Cotter Pin Spacer Plunger, Rubber Washer, Fiber Sleeve Nut, Compression Publication Number: 638085278 - 35 - © 2002-2014, Cornelius Inc.
  • Page 40 Continuous Flow Icemaker Installation and Service Manual Figure 30. Front End Assembly Model 500 Series Exploded View and Parts List Item Part No. Description Item Part No. Description 638090053 E-Ring 638090130 Front End Assembly-WCC500 638007302-06 Washer, Lock 1/4 Split 638090130-002...
  • Page 41 Gearmotor, 115V Without Service Kit 638090220 Bearing Delrin 638090001-002 Gearmotor, 220V 50 Hz Without Service 638090001-001 Gearmotor, 208/23-V 60Hz 638090215 Shaft Seal Mount 638090051 Shaft Seal 638007301-030 Washer, Lower 638090053 E-Ring Publication Number: 638085278 - 37 - © 2002-2014, Cornelius Inc.
  • Page 42 Gearmotor Assy-WCC1002& 2002 with Service Kit 638090326 Expansion Valve, Thermal 638090315 Shaft Seal Mount 638090349 Bracket, Mounting 638036042 O-Ring 638007106–03 Screw, 1/4 x 3/4 FHSC 638090051 Shaft Seal 638007301–030 Washer, Lower © 2002-2014, Cornelius Inc. - 38 - Publication Number: 638085278...
  • Page 43 Bin Probe Holder, WCC 638036079 638036079 638036079 Bin Probe Holder, WCF 638009387 638009387 638009387 Switch – Bin Control 638007341–03 638007341–03 638007341–03 Strain Relief 638007352–01 638007352–01 638007352–01 Bushing NOTE: * Not Shown Publication Number: 638085278 - 39 - © 2002-2014, Cornelius Inc.
  • Page 44 WCC1001 and WCF1101 638090244 Capacitor Start, 220V 50 Hz WCC1002 and WCF1102 41044 Capacitor Start, 208/230 V 60 Hz. WCC2001 and WCF2201 161165013 Capacitor Start, 220 V 50 Hz. WCC2002 and WCF2202 © 2002-2014, Cornelius Inc. - 40 - Publication Number: 638085278...
  • Page 46 Cornelius Inc. www.cornelius.com...

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