Cornelius 2400 (R404A) manual

MODULAR FLAKED ICE MAKER MODELS: SERIES 750 (R404a), SERIES 1 100 (R22), SERIES 2400 (R404a) Service Manual PRINTED IN U.S.A IMI CORNELIUS INC; 10/94 - 10/95  Part No. 166240009 OCTOBER 1994 Revised October , 1996 THIS DOCUMENT CONT AINS IMPORT ANT INFORMA TION This Manual must be read and understood before installing or operating this equipment[...]

i 166240009 T ABLE OF CONTENTS Page INTRODUCTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICA TIONS 750 AND 1 100 SERIES 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICA TIONS 2400 SERIES 4 . . . . . . . . . . . . . . . . . . . . [...]

ii 166240009 T ABLE OF CONTENTS (cont’d) LIST OF FIGURES Page FIGURE 1. 750 AND 1 100 SERIES SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . FIGURE 2. SPECIFICA TIONS FOR 2400 SERIES 4 . . . . . . . . . . . . . . . . . . . . . . . . . FIGURE 3. W A TER LEVEL 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

1 166240009 INTRODUCTION We have strived to produce a quality product. The design has been kept simple thus insuring trouble – free operation. This manual has been prepared to assist servicemen and users with information concerning installation, construction and maintenance of the ice making equipment. The problems of the serviceman and user have[...]

2 166240009 SPECIFICA TIONS 750 AND 1 100 SERIES A B C D E 8 1/4-IN. 21-CM 5 1/16-IN. 13-CM 5-IN. 13-CM 9-IN. 23-CM CHUTE OPENING FRONT BOTT OM VIEW REAR VIEW A = POWER INLET B = W A TER INLET C = CONDENSER (WA TER IN) (WC ONL Y) D = CONDENSER (WA TER OUT) (WC ONL Y) E = CHASSIS DRAIN 1 1/2-IN. 4-CM 1 3/4-IN. 4-CM 1 1 1/2-IN. 29-CM 2-IN. 5-CM 23 1/[...]

3 166240009 ICE PRODUCTION CAP ACITY (approximate) RF-1 100-P-MH PRODUCTION CHART AIR TEMPERA TURE W A TER TEMPERA TURE 50 ° F/10 ° C 60 ° F/16 ° C 70 ° F/21 ° C 70 ° F/21 ° C 1202 lbs/545 kgs 80 ° F/27 ° C 1 1 19 lbs/508 kgs 90 ° F/32 ° C 988 lbs/448 kgs 750 1 100 Compressor Electrical Rating 3/4 hp 2 hp Compressor Model Copeland RS64C[...]

4 166240009 SPECIFICA TIONS 2400 SERIES AIR IN NOTE: AIR IS EXHAUSTED OUT BACK AND SIDE OPPOSITE CONDENSER OVERALL DIMENSIONS 23-9/16-IN. HIGH x 45-1/8-IN. WIDE x 27-5/16-IN. DEEP CONDENSER SIDE AB ” A ” - AL TERNA TE ICE DROP AREA FOR TOP UNIT WHEN TWO ARE ST ACKED. ” B ” -ICE DROP AREA FOR BASIC UNIT . INDIVIDUAL ” A ” & ” B ”[...]

5 166240009 INST ALLA TION INSTRUCTIONS Y ou will get better service from the ice machine, longer life and greater convenience if you choose its location with care. Here are a few points to consider: 1. Select a location as close as possible to where you are going to use the ice. 2. Allow a minimum of 6 ” space at sides and rear of machine for ve[...]

6 166240009 14. T urn machine on and check for proper voltage and amp draw on the entire unit as well as components such as the gearmotor and fan motor . 15. Check refrigerant circuit and all plumbing connections for leaks, etc. 16. Check bin thermostat or mechanical shut – of f for proper operations. In the mid – range the bin thermostat will [...]

7 166240009 W ARNING: W A TER LEVEL MUST BE MAINT AINED A T THE T OP OF THE EV APORA TOR. W A T ER LEVEL ill224 FIGURE 3. W A TER LEVEL 1. Remove gearmotor and auger . 2. Adjust float valve to get water level to top seam of the evaporator . 3. Re – install auger. W A TER LEVEL WILL RISE WHEN AUGER IS INSER TED BUT WHEN THE MACHINE IS TURNED BACK [...]

8 166240009 ST ACKING INSTRUCTIONS FOR ST ACKING KIT 29757 The Kit consists of: 1 – #26102 Sealer 2 – #261 1/4-20x5/8 screw 2 – #256 1/4 ” flat washer 2 – #239 1/4 ” Lock W asher 1 – #29758 Stacking Chute Extension 1. After uncrating machine to be stacked, remove front and rear panels. 2. Remove top and front panels of bottom machine.[...]

9 166240009 TYPICAL W A TER CIRCUIT The supply water enters the float chamber through a small orifice. The water level rises and lifts the buoyant float with it. The float attached to the float arm seats a valve to shut off any further water supply . As water leaves the float chamber , the level drops along with the float and arm, causing the valve[...]

10 166240009 TYPICAL REFRIGERANT CIRCUIT Heat always flows from hot to cold and therefore, the ” heat load ” supplied to the evaporator section by water gives up its heat to the refrigerant which is at a temperature below the freezing point of water . This refrigerant now passes through the heat exchanger back to the compressor , as a low press[...]

11 166240009 ELECTRICAL CIRCUIT CIRCUIT DESCRIPTION As the manual on – off – circuit breaker switch is pushed to ” on ” , an electrical circuit is completed to the gearmotor via the circuit breaker gearmotor overload, power relay / contactor , gearmotor delay thermostat and the bin thermostat. After the previous circuit has been completed t[...]

12 166240009 COMPRESSOR ST ART RELA Y This is a current type relay and contains a N.O. contact which is connected in series with the start winding of the compressor . The relay coil is electrically in series with the run winding. When power is applied, the compressor draws high current which sets up a magnetic field around the magnet coil which cau[...]

13 166240009 GEAR MOTOR M 5 1 2 OR ST ART CAP ACITOR 72-86 MFD 330 VAC COMPRESSOR ST ART RELA Y COMPRESSOR RATED 2.0 AMPS CIRCUIT BREAKER ON-OFF SWITCH 3 ST ART CAP ACITOR GEAR MOTOR 4 64-77 MFD 165 VAC BL BK THERMOST A T DELA Y ST ART RELA Y GEAR MOTOR 2 LOW AMBIENT BL BL GR YL OUTLET BOX BL BIN YL RD WH THERMOST A T C R S CONTACTOR OVERL OAD COMP[...]

14 166240009 AF750PMH-50-R 220 VOL TS 50 Hz MOTOR GEAR M F AN MOTOR M COMPRESSOR ST ART CAP ACITOR M L S 88-106 MFD 220 V ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS GEAR MOTOR 4 CAP ACITOR ST ART 3 BK THERMOST A T DELA Y 2 ST ART RELA Y GEAR MOTOR BL YL GN/Y OUTLET BOX BIN LB BR RD THERMOST A T R S C 1 COMPRESSOR CONTACTOR F AN SWITCH COMPRESSOR [...]

15 166240009 MOTOR GEAR A/C ONL Y F AN MOTOR M OR 2 COMPRESSOR CAP ACITOR ST ART 1 5 ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS CAP ACITOR ST ART 2 GEAR MOTOR EVAPORATOR HEA TER DELA Y THERMOST A T GEAR MOTOR 4 3 ST ART RELA Y BL YL BOX OUTLET GR BIN RD BK THERMOST A T RUN R S C CONTROL (W/C ONL Y) COMPRESSOR AF/WF-1100-MH POWER RELAY HIGH PRESSU[...]

16 166240009 MOTOR GEAR WH FAN CLAS S II M M OR ST ART 1 5 2 TRANSFORMER ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS ST ART 3 GEAR MOTOR COOLING CAP ACITOR RELA Y POWER 4 WIRING 24V FIELD M DELA Y THERMOST A T 2 ST ART RELA Y GEAR MOTOR BL YL BOX OUTLET GW BIN RD BK THERMOST A T RUN 230V CONDENSER REMOTE C R S CONTROL HIGH PRESSURE CONTACTOR COMPR[...]

17 166240009 MOTOR GEAR M ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS ST ART 3 GEAR MOTOR CAP ACITOR M 4 F AN MOTOR DELA Y THERMOST A T 2 ST ART RELA Y GEAR MOTOR BL YL BOX OUTLET GR BIN RD BK THERMOST A T COMPRESSOR M CONTROL (W/C ONL Y) HIGH PRESSURE CONTACTOR AF/WF-1100-MH-3 3 PHASE 208/230 VOL TS 60 Hz BL BL BL RD BK RD BK BK RD BK RD BL RD RD[...]

18 166240009 MOTOR GEAR M OR 1 COMPRESSOR CAP ACITOR ST ART 2 5 ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS 3 GEAR MOTOR CAP ACITOR M 4 F AN MOTOR ST ART DELA Y BK THERMOST A T 2 ST ART RELA Y GEAR MOTOR BL YL BOX OUTLET GW BIN LB BR RD THERMOST A T RUN R S C CONTROL (W/C ONL Y) HIGH PRESSURE CONTACTOR COMPRESSOR AF/WF-1100-MH-50 240 VOL TS 50 Hz [...]

19 166240009 PRESSURE CAP ACITOR W A TER SWITCH LOW CO 10 CI 20 PRESSURE BIN LIMIT CO 450 250V START CAP ACITOR RUN COMPRESSOR 370V 35 MFD COMPRESSOR 145-174 MFD 2 1 5 START RELA Y COMPRESSOR MOTOR GEAR S C R COMPRESSOR GW CONTACTOR SYSTEM 2 HIGH M MOTOR GEAR MAIN ON-OFF SWITCH FAN M COND. RA TED 1.5 AMPS CIRCUIT BREAKER ON-OFF SWITCH SWITCH MOTOR [...]

20 166240009 MAINTENANCE THE FOLLOWING MAINTENANCE SHOULD BE PERFORMED A T LEAST EVER Y SIX MONTHS ON FLAKED ICE MACHINES: 1. Check power supply with machine running for proper voltage. 2. Check water level in the float tank reservoir . W ater level should be maintained at the top of the evaporator . Adjust if necessary . (See illustration and adju[...]

21 166240009 SANITIZING AND CLEANING PROCEDURE 1. T urn switch to ” OFF ” to stop unit. 2. Remove top cabinet panel. CAUTION: Hazardous moving parts. Do not operate unit with panel removed. 3. Mix sanitizing solution by using 0.5-ounces of household liquid bleach (such as Hi-Lex or Chlorox) to one gallon of potable water . This mixture must not[...]

22 166240009 W A TER TREA TMENT During the freezing process, as water passes under the freezing plate, the impurities in the water have a ten- dency to be rejected and the plate will freeze only the pure water . However , the more dissolved solids in the water , the more troublesome the freezing operation will be. Bicarbon- ates in the water are th[...]

23 166240009 TROUBLESHOOTING T rouble Probable Cause Remedy UNIT WILL NOT RUN A. On – off switch in ” of f ” position. A. T urn switch to ” on ” . B. Defective on – off switch. B. Check and replace. C. Blown fuse. C. Replace fuse and check for cause of blown fuse. D. Thermostat set too warm for ambient. D. Adjust colder . E. Power relay[...]

24 166240009 T rouble Remedy Probable Cause MAKING WET ICE. A. Surrounding air temperature too high. A. Correct or move unit B. High water level in float reservoir . B. Lower water level, see step 2, page 5 C. Dirty condenser . C. Clean condenser D. Faulty compressor . D. Check and replace E. Refrigerant leak. E. Check and repair F. ” O ” ring [...]

25 166240009 T rouble Remedy Probable Cause UNIT OFF OR TRIPS CIRCUIT BREAKER. A. Ice jams up in evaporator shell. A. Clean inside surface of evaporator shell. B. Bin thermostat will not shut – off machine. Set too cold. B. Check and adjust or replace . C. Auger motor has worn bearings. C. Check and replace. D. Ice chute out of alignment, restric[...]

26 166240009 T rouble Remedy Probable Cause UNIT GOES OFF OR TRIPS CIRCUIT BREAKER. (CONT ’ D) L. Plugged expansion valve, or capillary tube causing low back pressure. L. Check back pressure, replace valve or capillary tube. Evacuate and re – charge system, replace drier – strainer . M. Slight leak, causing low back pressure. M. Check back pr[...]

27 166240009 P ARTS LIST FOR 750 AND 1 100 SERIES ILL. NO . DESCRIPTION 1 100 750 1 100 – 50Hz 750 – 50Hz 1 Shroud, condenser 27597 161890012 27597 161890012 2 Condenser 26266 161870004 26266 161870004 3 Bracket, fan motor 37977 163183006 37977 163183006 4 Blade, condenser fan 23527 165595003 23527 165595003 5 Motor , condenser fan 35961 161871[...]

28 166240009 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ill227 50 51 FIGURE 13. ILLUSTRA TED P ARTS BREAKDOWN SERIES 750 – 1 100[...]

29 166240009 1 2 3 4 5 6 7 8 9 10 11 12 13 14 FIGURE 14. REMOTE CONDENSER ILLUSTRA TED P ARTS BREAKDOWN FOR 1 100 SERIES ILL. NO. P ART NO. DESCRIPTION 1 27334 Condenser 2 27149 Shroud 3 27576 Frame assy 4 27183 Fan blade 5 27185 Motor , fa n 6 27384 Bracket, fan motor mounting 7 27181 Relay 8 27379 Cover , electrical box 9 27345 Electrical box ass[...]

30 166240009 P ARTS LIST 2400 SERIES ITEM NO DESCRIPTION P ART NO. 1 Condenser A/C 16187001 1 2 Fan mounting bracket 164820021 3 Fan motor 27185 4 Fan blade 27183 5 Drier 166184002 6 Masonite Pad 26124 7 Hold – down 163277003 8 Evaporator 42597 9 Evaporator O – Ring 03120 10 Auger 21078 1 1 Shell L.H. 162966001 12 Shell R.H. 162966002 13 Automa[...]

31 166240009 1 2 3 4 5 5 6 6 7 7 8 8 9 10 10 11 12 13 13 14 14 15 16 17 18 19 20 20 21 22 23 24 25 26 27 28 28 29 29 30 31 32 33 32 33 34 35 35 36 36 37 37 38 38 39 40 41 42 43 44 FIGURE 15. ILLUSTRA TED P ARTS BREAKDOWN SERIES 2400[...]

P/N 163238002 Effective March. 1, 1996 Starting with Production Serial Number Code 9603 IMI CORNELIUS INC. ONE CORNELIUS PLACE ANOKA, MINNESOT A 55303-6234 166240010 32 CORNELIUS LIMITED COMMERCIAL W ARRANTY PLAN TO THE ORIGINAL OWNER OF A CORNELIUS COMMERCIAL FLAKE ICEMAKER This warranty applies to Icemakers installed within the United States, Can[...]

166240010 33 THIS P AGE LEFT BLANK INTENTIONALL Y[...]

One Cornelius Place Anoka, Minnesota 55303-6234 (763) 421-6120 (800) 238-3600 Corporate Headquarters: IMI CORNELIUS INC. 166240010 34[...]