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Model CCM and CCU Series Service and Maintenance Manual Publication Number: 631806061 Revision Date: May 1, 2008 Revision: B Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs. CCM and CCU Series Service and Maintenance Manual Manual Number 631806061...
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Table of Contents General Information How To Use This Manual Model And Serial Number Format Electrical And Mechanical Specifications Installation Guidelines Electrical And Plumbing Requirements Remote Condenser Installation How The Machine Works Undercounter Model Bin Removal Scheduled Maintenance Maintenance Procedure Cleaning and Sanitizing Instructions Winterizing Procedure Cabinet Care...
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General Information How To Use This Manual Cornelius provides this manual as an aid to the service technician in installation, operation, and maintenance of the CCM/CCU Series (electro-mechanical) cube ice machines. If used properly this manual can also assist the service technician to troubleshoot and diagnose most of the problems that may occur with the machine.
Condenser Type: A=Air, W=Water, R=Remote Cabinet Width (in inches) Approximate Production X 10 in 24 hours 70°F Air / 50°F Water Series: Cornelius Cuber Modular (U=Undercounter) Large data plate will be placed on the back of the unit. Serial Number...
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Electrical and Mechanical Specifications, “CCM/CCU” Series Ref. Charge Model Type Ounces CCM2148W2 1 R-404a CCM2148R2 1 R-404a CCM2148W3 R-404a CCM2148R3 R-404a CCM2148W3 1 R-404a CCM2148R3 1 R-404a Ref. Charge Model Type Ounces CCU0220A5 R-404a CCU0220W5 R-404a CCU0330A5 R-404a CCU0330W5 R-404a CCM0330A5 R-404a CCM0330W5...
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Note: Installation should be performed by a Cornelius trained Service Technician. For proper operation of the Cornelius ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failures, and may void all warranties.
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General Information Electrical and Plumbing Requirements: CCU0150 and CCU0220 Note: The CCU0150 and CCU0220 do not have a splash curtain. These models utilize a thermostatic bin control in place of a mechanical bin switch. Page A7...
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General Information Electrical and Plumbing Requirements: CCU0300 Note: The CCU0300 does not have a splash curtain. This model utilize a thermostatic bin control in place of a mechanical bin switch. Page A8...
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General Information Electrical and Plumbing Requirements: CCM0330, CCM0430, CCM0530, CCM0630, CCM0830 and CCM1030 (30 Inch Wide Cubers) Page A9...
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General Information Electrical and Plumbing Requirements: CCM1448**1, CCM1848**1, CCM2148**1 (48 Inch Wide Cubers) Page A10...
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General Information Electrical and Plumbing Requirements: CCM0322 and CCM0522 (22 Inch Wide Cubers) Page A11...
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General Information Electrical and Plumbing Requirements: CCM1530 Remote Page A12...
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Remote Condenser Installation For proper operation of the Cornelius ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failure, and may void all warranties. Use the following for planning the placement of the remote condenser relative to the ice machine.
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The following remote ice makers incorporate the mixing valve in the condenser. This configuration allows up to a 100 foot calculated remote line set run. Reference the diagram below to calculate the maximum 100 foot line set run. Ice Machine Model Number CCM2148R*1 CCM1848R*1 CCM1448R*1...
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General Information How the CCM/CCU ice machine works A general description of how the CMM/CCU series cubers work is given below. The remainder of the manual provides more detail about the components and systems. With the ICE/OFF/WASH switch in the ICE position, the compressor, water pump and condenser fan motor (when applicable) will energize starting the freeze cycle.
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General Information Undercounter Bin Removal-CCU0300 Series The storage bin can be removed by: Remove the lower grill. 2. Remove two screws securing bin to cabinet base. 3. Remove the thumbscrews from the back wall of the bin. 3. Remove the thumbscrews from the back wall of the bin. 4.
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General Information Undercounter Bin Removal-CCU0150/0220 Series The storage bin can be removed by: 1. Remove the two screws at the rear of the top panel. 2. Remove the two screws from the front panel. 3. Remove two screws securing bin to cabinet base. 4.
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Scheduled Maintenance Maintenance Note: Maintenance should be performed by a Cornelius trained Service Technician. Electrical shock and/or injury from moving parts inside this machine can cause serious injury. Disconnect electrical supply to machine prior to performing any adjustments or repairs.
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Cleaning and Sanitizing (continued) 5. Add recommended amount of approved Nickel Safe ice machine cleaner to the water trough according to label instructions on the container. 6. Initiate the wash cycle at the ICE/OFF/WASH switch by placing the switch in the “WASH” position.
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Winterizing Procedures Important! Whenever the ice machine is taken out of operation during the winter months, the procedure below must be performed. Failure to do so may cause serious damage. 1. Turn off water to machine. 2. Make sure all ice is off of the evaporator(s). If ice is being made, initiate harvest or wait for cycle completion.
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Cleaning stainless steel Commercial grades of stainless steel are susceptible to rusting. It is important that you properly care for the stainless steel surfaces of your ice machine and bin to avoid the possibility of rust or corrosion. Use the following recommended guidelines for keeping your stainless steel looking like new: 1.
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Troubleshooting Trees How To Use The Troubleshooting Trees The troubleshooting trees were developed to be used in conjunction with the service information in the sections that follow. If used together as intended, these two parts of the manual will allow the ice machine service technician to quickly diagnose many of the problems encountered with the ice machines.
Troubleshooting Trees Table Of Contents Machine Does Not Run Machine Runs, Does Not Make Ice Slow Production (Cube Formation Good) Low Suction Pressure High Suction Pressure Cubes Are Hollow Uneven Bridge Thickness Ice Bridge Thickness Varies Cycle To Cycle Machine Produces Cloudy Ice Poor Water Distribution Over Evaporator Machine Does Not Enter Harvest Machine Enters Harvest, Then Returns To Freeze Prematurely...
Machine Does Not Run Is the selector switch set to ICE? Set selector Switch to the ICE position Check for correct power supply to the machine Check High Pressure Safety Control Check High Temperature Safety Control Check Bin Control for proper adjustment, see page F9 GOOD...
Machine Runs, Does Not Make Ice Is water running over evaporator? Go to the Troubleshooting Tree on page Check High Pressure reset if necessary Continue if the machine has a remote condenser HIGH Check the suction pressure, is it low or high? Check refrigerant charge...
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Machine Runs, Does Not Make Ice (continued) Is water leaking out of the Purge Drain or Water Trough? Repair water leakage defect HIGH OR NORMAL SUCTION Check refrigerant pressures, see page LOW SUCTION Recover and weigh in refrigerant charge Low side restriction or defective TXV Page C5...
Slow Production (Cube Formation Good) Does installation meet guidelines? Correct any installation defects Check for excessive head pressure TOO HIGH Is this unit air cooled or water cooled? WATER Check Water Regulating Valve, See page E2 See Condenser service information page E2 Page C6 Troubleshooting Trees...
Low Suction Pressure Does installation meet guidelines? Is the water flow over the Evaporator correct? Check for correct head pressure, see page E10 DRY SYSTEM Check TXV for moisture based restriction WET SYSTEM Replace drier, evacuate and recharge system NOT OK Is the machine a remote unit?
High Suction Pressure Have you checked the “Slow Production” Tree? Is the head pressure also high? Is the machine installed to specifications? Is the Condenser dirty? Check for leaking Purge valve Go to “Slow Production” Troubleshooting Tree Check Hot Gas Valve, see page E5 Hot Gas Valve is possibility...
Cubes Are Hollow Is the water temperature above 100°F (38°C)? Water temperature too high, correct water temperature Is there good water flow over the Evaporator? Go to the “Poor Water Distribution Check Timer for Over Evaporator” proper setting, see Troubleshooting Tree, page C13 Timer Initiate Control out of...
Uneven Bridge Thickness Make sure supply water temperature is below 100°F (38°C) Check for water leaking out of Purge Drain Dirty or defective Purge Valve Is water running into the bin? Are the Evaporator(s) flooded? See page E4 and Check the suction pressure, is it high or low? See pageE1 Make sure the...
Ice bridge Thickness Varies Cycle To Cycle Is air and water temps consistent and within guidelines? Check the Purge Valve for water leaks Check Hot Gas valve for proper operation Check Timer Initiate Control for proper operation Check Solid State Timer for proper operation TXV(s) could be...
Machine Produces Cloudy Ice Is water running evenly across the evaporator? Doe machine meet installation guidelines? See Section A Cloudiness is a result of properties in the incoming supply water Page C12 Troubleshooting Trees See “Poor Water Running Over Evaporator Troubleshooting Tree page C13 Correct...
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Poor Water Distribution Over The Evaporator Is the machine level? Level the machine OBSTRUCTED Clean Water Distribution Tube; insure that it is assembled correctly Is the water level in the Water Trough correct? See Section D Check Water Distribution Tube for obstructions or improper assembly See Section D...
Machine Does Not Enter Harvest Will suction pressure drop below cut-in of Timer Initiate? Does the manual Purge Switch energize the Purge Valve? High Temperature Safety Control may be open, see page F8 Is the freeze pattern on the Evaporator even? Check for signs of a weak Compressor,...
Machine Enters Harvest, Then Returns To Freeze Prematurely Is the Harvest Assist working properly? See page F6 Adjust as required or replace defective part Check the Manual Purge Switch Normally Closed contacts. See page CLOSED Check High Temperature Safety Control. See page CLOSED Relay 1 or Relay Base may...
Length Of Harvest Excessive Does the machine meet installation guidelines? Check Harvest Assist Assembly for proper operation, see page F6 NOT OK Adjust or replace defective part Correct installation deficiency Is the ice formation even on the Evaporator? Does the machine have a remote condenser?
Ice Does Not Release From Evaporator Is the ice bridge correct? See page F4 Set proper bridge thickness, see page F4 NOT OK Check Purge valve and Tubing for obstructions and proper operation, see page D2 Check Relay 1 and Relay Base for proper operation, see page F5...
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Hot Evaporator, Low Suction And Discharge Pressure (Remote Only) Does the machine meet the installation guidelines? Does the machine have the proper refrigeration charge? Repair leak, evacuate and weigh in refrigerant charge per nameplate Correct installation deficiency Mixing Valve may be defective, see page E6 Page C18...
Water System Water Distribution and Components Water enters the machine through the float valve located in the water trough. The water trough holds water used for ice making. The float valve is used to maintain the proper water level in the water trough.
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Water System Water Distribution Disassembly Remove 2 screws holding the distribution tube to the evaporator spillway. Remove the clamp holding the water tube to the distribution tube. Twist the end caps of the distribution tube counterclockwise and pull to remove the inner tube halves from the outer tube. To reassemble, push the inner tube halves into the outer tube with the holes facing the same direction.
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Water Splash Curtain The water splash curtain covers the evaporator to prevent water from splashing into the bin and is also used to actuate the bin switch. When the bin becomes full of ice, the splash curtain is held open when the ice drops off of the evaporator. The actuator tab or wire bale on the splash curtain will release pressure on the bin switch and the machine shuts off.
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Water System Water Purge Valve When the machine enters the harvest cycle, the water pump continues to run and the purge valve opens. This allows mineral laden water to be pumped from the water trough to the drain. This helps keep the water system clean. The water pump and purge valve de-energizes once the water is flushed from the water trough.
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Water Trough The water trough can be easily removed by the following procedures: 1. Disconnect power to the ice machine. 2. Shut the water supply off to the ice machine. 3. Remove water splash curtains when applicable. 4. Remove water trough mounting screws. 5.
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Refrigeration System Refrigerant Cycle and Components Before diagnosing the refrigeration system, it is very important that the refrigerant charge be correct. Whenever the refrigeration system has been opened, the filter-drier must be replaced and the proper refrigerant charge must be weighed in.
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Refrigeration System Air Cooled Condenser (Self Contained) The air condenser is located in the back of the cabinet. Air is pulled through the condenser by a fan motor and discharged through the right hand side panel. The CCM1448 has 2 fan motors and discharges through the right side and left side panels.
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Thermostatic Expansion Valve (TXV) The thermostatic expansion valve meters the flow of refrigerant into the evaporator changing its state from a high-pressure liquid to a low-pressure liquid. This drop in pressure causes the refrigerant to cool. The cooled refrigerant absorbs heat from the water circulating over the evaporator. As the evaporator fills with liquid refrigerant, the evaporator becomes colder.
Thermostatic Expansion Valve (Continued) A dual evaporator machine will have one TXV for each evaporator. If one TXV sticks open and the other is operating normally, the suction pressure will be higher than normal and both evaporators will build thick ice. It is recommended that both valves be replace if one sticks open. If one TXV sticks closed and one is operating normally, the suction pressure will be normal or low but the evaporator with the defective valve will be starved (thick ice at the bottom and thin ice at the top).
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Note: Permanent discoloration of the evaporator plating is normal and will cause no problems with harvesting the ice or sanitary conditions. Before condemning the evaporator for plating problems, be certain it is not just discoloration. If the spillway (plastic evaporator top) becomes damaged, it can be replaced.
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Remote Condenser (Continued) If the airflow is restricted or the condenser is dirty, the head pressure will be excessively high, slow production will result and the compressor may overheat and eventually become damaged. The condenser coil and fan blades must be kept clean. The condenser can be cleaned with compressed air or by using a brush.
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Refrigeration System Pump Down System (Remote Only) The pump down system prevents liquid refrigerant from migrating to the evaporator and compressor during the off cycle and prevents the compressor from slugging or starting under an excessive load. Liquid Line Solenoid When a machine with a remote condenser shuts off, the liquid line solenoid valve, located at the outlet of the receiver, is de-energized causing the valve to close completely restricting the flow of refrigerant.
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Refrigeration System Refrigerant Refrigerant in a high-pressure liquid form is fed to an expansion valve where the refrigerant is reduced to a low-pressure liquid. Under this low pressure, the liquid will absorb heat from the evaporator causing the liquid to change to a vapor. This vapor is the drawn into the compressor where the temperature and pressure of the vapor are increased.
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Refrigeration System If the refrigeration system is extremely wet, use radiant heat to raise the temperature of the system. This action will cause the moisture to vaporize at less of a vacuum. The use of two (2) valves, one between the vacuum pump and gauge manifold and the other between the refrigerant cylinder and the gauge manifold allows you to evacuate and charge the system without disconnecting any hoses.
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Electrical System Control Circuit All machines in this manual are electro-mechanical controlled; however the control circuitry on the single evaporator units differs from the dual evaporator units and is detailed below. Selector Switch The selector switch is used to put the machine into the ICE making or WASH cycle or to turn the machine OFF.
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Electrical System Compressor Check (Continued) If all starting components are good, check the amperage draw from the common terminal of the compressor, making sure proper voltage is supplied to the compressor and all wiring is properly connected. If the compressor does not start and there is excessive amperage draw, (see locked rotor amps on compressor tag) the compressor has a locked rotor and should be replaced.
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Electrical System Untimed Freeze Cycle During the freeze cycle the compressor, water pump and condenser fan motor(s) (if used) are running. On remote systems the liquid line solenoid is also energized, see Refrigeration System. As ice forms on the evaporator, the suction pressure drops. The machine is in the untimed portion of the freeze cycle and will remain in untimed freeze until the suction pressure drops low enough to close the timer initiate control.
ON will provide an initial timer setting. The ice bridge thickness should be approximately 3/16” (5mm) on the CCU undercounter series, CCM0330 and CCU0300, and 1/8” (3 mm) on CCM0430 and larger units. If the bridge is too thick, remove enough time from the timer to achieve proper thickness.
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Electrical System Harvest Cycle Single Evaporator Machines Once the freeze timer has timed out, power is sent to relay 1 and the machine enters the harvest cycle. Once in harvest motor, the purge valve, hot gas valve and harvest motor are energized. The water pump continues to run during the first part of the harvest cycle so that mineral laden water remaining in the water trough can be pumped through the purge valve to the drain.
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Electrical System Harvest Assist Assembly The harvest assist assembly has several purposes: to assist in moving the ice off of the evaporator, to control the length of harvest and to terminate harvest. When the machine enters harvest, power is sent to the harvest motor which turns a slip clutch.
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Probe Tip and Swivel The probe tip is attached to the clutch and makes contact with the back of the ice slab during harvest. The swivel allows the probe tip to pivot as the clutch turns so that the probe is pushed straight through the evaporator probe guide.
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Cam Switch Adjustment Check the cam switch for proper adjustment by slowing turning the clutch by hand in a counterclockwise direction while listening for the switch contacts to change. The switch should have an audible “click” as the roller reaches the high part of the cam. Now slowly turn the clutch in a clockwise direction and the switch should have an audible “click”...
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Electrical System Undercounter machines: A thermostatic bin control is used on the undercounter models. The bin thermostat is located in the control box with a capillary tube, which is in a brass thermo-well mounted to the water trough. When ice comes in contact with the capillary tube thermo-well, the bin thermostat opens and the machine will shut off.
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Electrical Sequence for the CCM1448***1, CCM1848***1 and the CCM2148***1 Cubers. (Manufactured from January, 2008) CCM1448*A/W*1, CCM1848*W*1 and CCM2148*W**1 Electrical Sequence (Includes 50 hz. And 3 Phase) 1. Suction Pressure starts out at approx 60 psi and slowly drops to close the LP Control. 2.
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Electrical Sequence for the CCM1448***1, CCM1848***1 and the CCM2148***1 Cubers. (Manufactured from January, 2008) CCM1448*R*1, CCM1848*R*1 and CCM2148*R*1 Electrical Sequence (Includes 50 hz. And 3 Phase) This unit incorporates a timer upstream of the Low Pressure Control for Low Ambients. 1.
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Electrical Sequence for the CCM1530*R21 (Manufactured from January, 2008) This unit incorporates a timer upstream of the Low Pressure Control for Low Ambients. 1. When the Selector Switch is set to ICE, Relay Number 2 Coil is energized through Cam Switch contacts C and NC (Bypasses the Bin Controls) 2.
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Table of Contents General Information How To Use This Manual Model And Serial Number Format Electrical And Mechanical Specifications Installation Guidelines Electrical And Plumbing Requirements Remote Condenser Installation How The Machine Works Undercounter Model Bin Removal Scheduled Maintenance Maintenance Procedure Cleaning and Sanitizing Instructions Winterizing Procedure Cabinet Care...
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Wiring Diagram CCU0150/220 Air and Water Wiring Diagram includes 230 Volt and 50 Cycle Page G1...
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Wiring Diagram CCU0150/220 Air and Water Wiring Schematic Includes 230 Volt and 50 Cycle Page G2...
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Wiring Diagram CCM0830/CCM1030 Air and Water Wiring Diagram Includes 50 Cycle Page G3...
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Wiring Diagram CCM0830/CCM1030 Air and Water Wiring Schematic Includes 50 Cycle Page G4...
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Wiring Diagram CCU0300, 115V, Air and Water Wiring Diagram Page G21...
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Wiring Diagram CCU0300, 115V, Air and Water Wiring Schematic Page G22...
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Wiring Diagram CCU0300, 50 Cycle, Air and Water Wiring Diagram Page G23...
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Wiring Diagram CCU0300, 50 Cycle, Air and Water Wiring Schematic Page G24...
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Wiring Diagram CCM0330/CCM0430, 115V, Air and Water Wiring Diagram Page G25...
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Wiring Diagram CCM0330/CCM0430, 115V, Air and Water Wiring Schematic Page G26...
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Wiring Diagram CCM0322/CCM0522, 115V, Air and Water Wiring Diagram Page G27...
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Wiring Diagram CCM0322/CCM0522, 115V, Air and Water Wiring Schematic Page G28...
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Wiring Diagram CCM0330/CCM0430 Air and Water Wiring Diagram Includes 230/60/1 and 50 Cycle Page G29...
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Wiring Diagram CCM0330/CCM0430 Air and Water Wiring Schematic CCM0330/CCM0430 Air and Water Wiring Schematic Includes 230/60/1 and 50 Cycle Includes 230/60/1 and 50 Cycle Page G30...
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Wiring Diagram CCM0322/CCM0522, 50 Cycle, Air and Water Wiring Diagram Page G31...
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Wiring Diagram CCM0322/CCM0522, 50 Cycle, Air and Water Wiring Schematic Page G32...
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Wiring Diagram CCM0530 Air and Water Wiring Diagram Page G33...
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Wiring Diagram CCM0530 Air and Water Wiring Schematic Page G34...