Cornelius Ice Maker Series 200 User Manual

®
SELF-CONTAINTED  
FLAKED ICE MAKER  
Model: Series 200, 525, 725 (R404A Refrigerant)  
Service Manual  
Series 200  
Release Date: May 13, 2004  
Publication Number: 166240010SER  
Revision Date: NA  
Revision: A  
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TABLE OF CONTENTS  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Specifications 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Ice Production Capacity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Specifications 525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Ice Production Capacity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
Specifications 725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Ice Production Capacity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  
Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
On-Off Switch/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Bin Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
High Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Gearmotor Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Power Relay/Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Fan Cycling Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Delay Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Compressor Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Potential Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Capacitors - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Sanitizing and Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Winter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Cleaning the Condenser (Air Cooled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
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Self-Contained Flaked Ice Maker Service Manual  
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 been given special attention in the development and engineering of our ice makers.  
If you encounter a problem which is not covered in this manual, please feel free to write or call. We will be  
happy to assist you in any way we can.  
When writing, please state the model and serial number of the machine.  
© 2004, IMI Cornelius Inc.  
- 1 -  
Publication Number: 166240010SER  
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Self-Contained Flaked Ice Maker Service Manual  
SPECIFICATIONS 200  
26 1/2-IN.  
67-CM  
13 1/2-IN.  
34-CM  
4-IN.  
10-CM  
7-IN.  
18-CM  
ON-OFF  
S WITCH  
R E AR VIE W  
OF CABINE T  
3/4-IN.  
2-CM  
5-IN.  
13-CM  
E LE CTR ICAL  
BOX AR E A  
34-IN.  
86-CM  
A
B
26-IN.  
66-CM  
40-IN.  
C
102-CM  
19-IN.  
48-CM  
24 7/8-IN.  
63-CM  
AIR  
FLOW  
7-IN.  
25-IN.  
64-CM  
18-CM  
6-IN.  
15-CM  
A- 1/4 WATE R INLE TS  
(S .A.E . MALE FLAR E )  
B- 5/8 O.D. TUBE (DR AIN)  
C- 1/2 O.D. TUBE (DR AIN)  
FIGURE 1. 200 SERIES SPECIFICATIONS  
ICE PRODUCTION CAPACITY (APPROXIMATE)  
AF–200–P(S)–SCR PRODUCTION CHART  
AIR  
WATER TEMPERATURE  
TEMPERATURE  
50°F/10°C  
70°F/21°C  
80°F/27°C  
219 lbs/99 kgs  
188 lbs/85 kgs  
175 lbs/79 kgs  
166 lbs/75 kgs  
117 lbs/53 kgs  
50°F/10°C  
70°F/21°C  
90°F/27°C  
208 lbs/95 kgs  
161 lbs/35 kgs  
174 lbs/79 kgs  
130 lbs/59 kgs  
AF200PSC50R PRODUCTION CHART  
AIR  
WATER TEMPERATURE  
TEMPERATURE  
50°F/10°C  
70°F/21°C  
80°F/27°C  
234 lbs/106 kgs  
206 lbs/94 kgs  
197 lbs/90 kgs  
50°F/10°C  
70°F/21°C  
90°F/27°C  
213 lbs/97 kgs  
183 lbs/83 kgs  
190 lbs/86 kgs  
164 lbs/75 kgs  
180 lbs/82 kgs  
156 lbs/71 kgs  
Publication Number: 166240010SER  
- 2 -  
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© 2004, IMI Cornelius Inc.  
Self-Contained Flaked Ice Maker Service Manual  
200  
Compressor Model  
Copeland JS25CIEIAA203 (115V 60HZ)  
Copeland AS13CIE1AZ908 (220V 50HZ)  
Condenser  
Air Cooled  
Refrigerant Charge  
8 oz. R404a (115V 60HZ)  
7 oz. R404a (220V 50HZ)  
Refrigerant Control (115V 60HZ)  
Refrigerant Control (220V 50HZ)  
Inlet Water Supply  
Automatic Expansion Valve (28PSI)  
Automatic Expansion Valve (31PSI)  
1/4SAE male flare  
Voltage  
115V 60HZ or 220V 50HZ  
1/8 hp  
Gearmotor Electrical Rating  
Gearmotor Amp. Rating  
2 amps (115V 60 HZ)  
1 amp (220V 50HZ)  
Total Amp. Draw  
11.0 Amps (115V 60HZ)  
4.0 Amps (220V 50HZ)  
Maximum Fuse Size  
15 Amp (115V 60HZ)  
15 Amp (220V 50HZ)  
© 2004, IMI Cornelius Inc.  
- 3 -  
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Publication Number: 166240010SER  
Self-Contained Flaked Ice Maker Service Manual  
SPECIFICATIONS 525  
13 1/2-IN.  
34-CM  
2-IN.  
5-CM  
26 1/2-IN.  
67-CM  
3 1/2-IN.  
9-CM  
3 1/2-IN.  
9-CM  
2 1/2-IN.  
6-CM  
R E AR VIE W  
OF CABINE T  
E LE CTR ICAL  
BOX AR E A  
5/8-IN.  
2-CM  
A
ON-OFF  
S WITCH  
34-IN.  
86-CM  
5 5/8-IN.  
14-CM  
B
26-IN.  
66-CM  
19 1/2-IN.  
50-CM  
3 5/8-IN.  
9-CM  
D
E
C
40-IN.  
102-CM  
MIN.  
AIR IN  
24 3/4-IN.  
63-CM  
4 5/8-IN.  
12-CM  
3 3/4-IN.  
10-CM  
38 3/4-IN.  
97-CM  
26 3/8-IN.  
67-CM  
14-IN.  
36-CM  
6-IN.  
15-CM  
MIN.  
3 3/8-IN.  
9-CM  
A- 3/8 WATE R INLE T (S .A.E . MALE FLAR E )  
B- 1/2 O.D. TUBE (CONDE NS ATE DR AIN)  
C- 3/4 N.P.T. BIN DR AIN  
D- CONDE NS E R WATE R IN (W/C ONLY)  
E - CONDE NS E R WATE R OUT (W/C ONLY)  
FIGURE 2. 525 SERIES SPECIFICATIONS  
ICE PRODUCTION CAPACITY (APPROXIMATE)  
AF525P(S)SCR PRODUCTION CHART  
AIR  
WATER TEMPERATURE  
TEMPERATURE  
50°F/10°C  
70°F/21°C  
80°F/27°C  
654 lbs/297 kgs  
588 lbs/267 kgs  
552 lbs/251 kgs  
521 lbs/237 kgs  
448 lbs/204 kgs  
50°F/10°C  
70°F/21°C  
90°F/27°C  
639 lbs/290 kgs  
562 lbs/255 kgs  
563 lbs/256 kgs  
479 lbs/218 kgs  
AF525PSC50R PRODUCTION CHART  
AIR  
WATER TEMPERATURE  
TEMPERATURE  
50°F/10°C  
70°F/21°C  
80°F/27°C  
629 lbs/286 kgs  
528 lbs/240 kgs  
494 lbs/225 kgs  
50°F/10°C  
70°F/21°C  
90°F/27°C  
621 lbs/282 kgs  
493 lbs/224 kgs  
525 lbs/239 kgs  
414 lbs/188 kgs  
489 lbs/222 kgs  
387 lbs/176 kgs  
Publication Number: 166240010SER  
- 4 -  
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© 2004, IMI Cornelius Inc.  
Self-Contained Flaked Ice Maker Service Manual  
525  
Compressor Model  
Copeland RS43CIEIAA214 (115V 60HZ)  
Copeland RS43CIEIAZ214 (220V 50HZ)  
Condenser  
Air Cooled  
Refrigerant Charge  
Refrigerant Control  
Inlet Water Supply  
Voltage  
17 oz. R-404a  
Automatic Expansion Valve (34PSI)  
3/8SAE Male Flare  
115V 60HZ or 220V 50HZ  
Total Amp Draw  
15.5 Amps (115V 60HZ)  
6.0 Amps (220V 50HZ)  
Gearmotor Amp Draw  
2 Amps (115V 60HZ)  
1 Amp (220V 50HZ)  
Gearmotor Electrical Rating  
Maximum Fuse Size  
1/8 hp  
20 Amp (115V 60HZ)  
15 Amp (220V 50HZ)  
© 2004, IMI Cornelius Inc.  
- 5 -  
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Publication Number: 166240010SER  
Self-Contained Flaked Ice Maker Service Manual  
SPECIFICATIONS 725  
30-IN.  
76-CM  
17 1/8-IN.  
43-CM  
2 3/8-IN.  
6-CM  
2-IN.  
5-CM  
2 3/4-IN.  
7-CM  
2 1/2-IN.  
6-CM  
ON-OFF  
S WITCH  
R E AR VIE W  
OF CABINE T  
E LE CTR ICAL  
BOX AR E A  
34-IN.  
5/8-IN.  
86-CM  
2-CM  
A
5 5/8-IN.  
14-CM  
26-IN.  
66-CM  
40-IN.  
102-CM  
MIN.  
19 1/2-IN.  
50-CM  
B
D
E
C
AIR IN  
28 3/8-IN.  
72-CM  
48-IN.  
122-CM  
5 1/32-IN.  
13-CM  
32 1/16-IN.  
81-CM  
4 1/2-IN.  
11-C M  
16 3/8-IN.  
42-CM  
6-IN.  
15-CM  
3 1/4-IN.  
8-CM  
4-IN.  
10-CM  
A- 3/8 WATE R INLE T (S .A.E . MALE FLAR E )  
B- 1/2 O.D. TUBE (CONDE NS ATE DR AIN)  
C- 3/4 N.P.T. BIN DR AIN  
D- CONDE NS E R WATE R IN (W/C ONLY)  
E - CONDE NS E R WATE R OUT (W/C ONLY)  
FIGURE 3. 725 SERIES SPECIFICATIONS  
ICE PRODUCTION CAPACITY (APPROXIMATE)  
AF725PSCR PRODUCTION CHART  
AIR  
WATER TEMPERATURE  
TEMPERATURE  
50°F/10°C  
70°F/21°C  
80°F/27°C  
654 lbs/297 kgs  
588 lbs/267 kgs  
552 lbs/251 kgs  
521 lbs/237 kgs  
448 lbs/204 kgs  
50°F/10°C  
70°F/21°C  
90°F/27°C  
639 lbs/290 kgs  
562 lbs/255 kgs  
563 lbs/256 kgs  
479 lbs/218 kgs  
725  
Compressor Model  
Condenser  
Copeland RS43CIE-IAA-214  
Air Cooled  
Refrigerant Charge  
Refrigerant Control  
Inlet Water Supply  
Voltage  
17 oz. R-404a  
Automatic Expansion Valve (34PSI)  
3/8SAE Male Flare  
115V 60HZ  
Total Amp Draw  
Gearmotor Amp Draw  
15.5 Amps  
2 Amps  
Gearmotor Electrical Rating  
Maximum Fuse Size  
1/8 hp  
20 Amp  
Publication Number: 166240010SER  
- 6 -  
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© 2004, IMI Cornelius Inc.  
Self-Contained Flaked Ice Maker Service Manual  
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 the condenser fan motor will start  
as will the compressor (via the high pressure control, the compressor starting relay and low ambient  
control).  
On-Off Switch/Circuit Breaker  
This switch interrupts power to the entire unit. The switch has a circuit breaker incorporated into its’  
design. This circuit breaker will trip out in the event the gearmotor draws to high of amps. In such an  
event the power is interrupted to the unit. To reset the circuit breaker and reestablish power to the unit,  
push the switch to the offposition and then back to the onposition.  
Bin Thermostat  
This is electrically in serieswith the ice making system. When the bin is full, the contact opens,  
terminating power to the machine.  
High Pressure Control  
Switch contact will open at 450 PSI for R404a breaking the circuit to the compressor. This control is  
manually re-settable.  
Gearmotor Start Relay  
This is a current type relay which means as the gearmotor run winding comes onthe line, the current  
draw initially is relatively heavy through the relay coil (coil is in series with run winding). It then acts like a  
normal relay and the N.O. start contact makes, completing a circuit through the start capacitor to the  
start winding. As the gearmotor picks up speed, the amp draw through the relay coil drops off allowing  
the armature to return to its normal position (start contact opens). This action removes the start winding  
from the circuit.  
Power Relay/Contactor  
This relay controls the compressor power only.  
Fan Cycling Switch  
The function of this switch is to maintain condensing pressures at a satisfactory level during-low ambient  
conditions. The switch breaks the circuit to the condenser fan motor at 205 PSI and makes the circuit at  
275 PSI.  
Delay Thermostat  
This thermostat keeps the gearmotor running until the suction line temperature reaches 45° after the full  
bin switch terminates power to the power relay.  
Compressor Start Relay  
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 in the magnet coil which  
causes the relay to operate, closing the relay contact. As the compressor approaches operating speed,  
the current flowing through the coil decreases, permitting the relay contact to open, thereby opening the  
starting circuit.  
© 2004, IMI Cornelius Inc.  
- 7 -  
Publication Number: 166240010SER  
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Potential Relays  
The potential relay is used as a compressor starting relay, The contact in the potential relay is N.C. The  
magnet coil is connected across (parallel) the start winding and is affected by induced voltage, generated  
by the start winding. As the compressor comes up to design speed, the voltage across the relay coil  
increases and at running speed is sometimes as much as 2 1/2 times the supply voltage. This voltage  
sets up a magnetic field which causes the relay to operate. The starting relay is calibrated to remove the  
start capacitor (open the starting circuit) at approximately 85% of the motor design speed.  
NOTE: BOTH TYPES OF RELAYS ARE DESIGNED TO OPERATE WITHIN VERY NARROW LIMITS  
OF VOLTAGE AND CURRENT DICTATED BY MOTOR DESIGN, THEREFORE, WHEN MAKING A  
REPLACEMENT OF A RELAY ALWAYS PROVIDE AN EXACT REPLACEMENT, RECOMMENDED  
BY THE COMPRESSOR MANUFACTURER.  
Capacitors - General  
An electrical capacitor is a device which stores up electrical energy. Capacitors are used with single  
phase motors to provide starting torque and improve running characteristics; by feeding this energy to  
the start winding in step with the run winding.  
Any capacitor has three (3) essential parts, two (2) of which are usually foil plates separated and  
insulated by the third part called the dielectric.  
Two general types of capacitors are used with electric motors. The electrolytic starting capacitor usually  
uses a very thin film of oxide on the metallic plate as the dielectric. The running capacitor usually is of the  
liquid filled type.  
Publication Number: 166240010SER  
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© 2004, IMI Cornelius Inc.  
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Self-Contained Flaked Ice Maker Service Manual  
MAINTENANCE  
IMPORTANT: THE FOLLOWING MAINTENANCE SHOULD BE PERFORMED AT LEAST EVERY SIX  
MONTHS ON FLAKED ICE MACHINES.  
1.  
2.  
Check power supply with machine running for proper voltage.  
Check water level in the float tank reservoir. Water level should be maintained at the top of the  
evaporator. Adjust if necessary. (See illustration and adjustment procedure)  
3.  
Clean the air-cooled condenser coil with a stiff brush or vacuum cleaner (See procedure).  
CAUTION: Condenser cooling fins are sharp, use care when cleaning.  
Clean the ice storage bin and flush the bin drain at least once a month.  
If a water conditioner is installed in the inlet water line, change, replace, or clean the filter, strainer  
or cartridge as required.  
4.  
5.  
6.  
If heavy mineral deposits on the auger and evaporator shell are encountered due to bad local water  
conditions, follow sanitizing and cleaning procedure.  
7.  
8.  
9.  
Loosen hold-down cam locks and remove gearmotor assembly.  
Check thrust washer; replace if noticeably worn.  
Lift out auger and examine for wear. The corkscrew auger guide bushing pressed into the drive  
block should be checked for wear. Replace if loose or if worn flat with auger drive block. If the Helix  
auger on the corkscrew auger round bar becomes flat on the inside more than 1/8 of an inch over a  
length of two inches or more it should be replaced.  
NOTE: HELIX AUGERS DO HAVE MACHINED FLAT RELIEF SURFACES. DONT CONFUSE THEM  
WITH WORN FLAT AREAS.  
Check the insert in the bottom ring of the Helix auger and replace if excessively worn.  
10. Check shell vertical strips for wear. Replace the shell if excessive wear is shown.  
11. Check O-Ring, replace if worn or cut.  
12. Re-assemble, steps 7 through 11.  
CAUTION: In re-assembling the auger gearmotor, the hold down clamps must be tight and secure.  
In re-installing the evaporator shell, be absolutely sure that the oring is not pinched off as this  
would cause a water leak around the base of the evaporator. Lubricate the oring with food grade  
lubricant before re-assembling shell.  
13. Check for alignment of ice chute. Make sure chute gasket is not blocking path of ice flow.  
14. Check bin thermostat operation. In the mid-range position the bin thermostat will open at 42° and  
has a 6° differential.  
SANITIZING AND CLEANING PROCEDURE  
1.  
2.  
Turn unit off at switch in upper rear right side panel.  
Turn water off and remove water hose from bottom of float chamber inside of ice bin and allow to  
drain from the evaporator via the hose end; or  
3.  
Remove float chamber cover and while holding float up to prevent more water from entering the  
float chamber, remove water hose from float chamber and proceed to drain the float chamber and  
evaporator.  
4.  
5.  
6.  
With water still off, restore water hose to float chamber and add 1/2 oz. of sanitizer(see note  
below). Turn water on.  
Remove the bin door, float chamber cover, ice chute trim cover, two thumb screws and chute trim  
gasket.  
Using soap, hot water, and a non-metallic bristle brush or plastic scouring pad, scrub the parts  
removed in step 4 as well as the interior of the ice bin, ice chute, thermowell, door tracks, ice bin  
top, and around bin opening.  
© 2004, IMI Cornelius Inc.  
- 9 -  
Publication Number: 166240010SER  
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NOTE: Use care when cleaning around thermowell sensing tube; the small capillary is easily  
broken. Rinse all parts in clean water.  
7.  
In a 5 gallon bucket, mix a sanitizing solution of 1/2 oz. of sanitizer to 1 gallon of warm water (100°  
to 120° F).  
8.  
9.  
Place all small, loose parts into the sanitizing solution and allow them to soak for 10 minutes.  
Using a clean cloth and the sanitizing solution, wipe down the interior of the ice chute, thermowell  
door tracks, ice bin top, and around bin opening. Allow to air dry.  
10. Reassemble the float chamber cover, ice chute gasket and cover, and bin door.  
11. Turn unit switch on and allow machine to make ice for at least 1/2 hour then discard all of the ice.  
DO NOT ALLOW ICE WITH SANITIZER IN IT TO BE USED.  
NOTE: APPROVED SANITIZER: Household bleach such as Hi-Lex or Clorox.  
WATER TREATMENT  
During the freezing process, the impurities in the water have a tendency to be rejected.  
However, the more dissolved solids in the water, the more troublesome the freezing operation will be.  
Bicarbonates in the water are the most troublesome of the impurities. These impurities will cause scaling  
on the evaporator, clogging of the float valve mechanism and other parts in the water system. If the  
concentration of impurities is high, wet mushy ice may be the result.  
Parts of the ice maker, that are in contact with the water or ice, may corrode if the water is high in acidity.  
In some areas, water may have to be treated in order to overcome some of the problems that arise  
because of the mineral content.  
IMI Cornelius has water filter/treatment systems available to control impurities found in your water supply.  
Contact your local dealer for more information.  
WINTER STORAGE  
If the unit is to be stored in an area where the temperature will drop below freezing, it is most important  
that all water lines be drained to prevent them from freezing and possible rupture.  
To blow out the water line, disconnect the water supply at the cabinet inlet and use air pressure to force  
the water into the water reservoir pan. This can then be removed from the water pan.  
WATER COOLED CONDENSER - To remove water from condenser unhook water supply and attach  
compressed air hose. Start machine. As head pressure reaches the appropriate level opening the water  
regulating valve, the compressed air will force the water out. Do not let the machine operate longer than  
necessary.  
CLEANING THE CONDENSER (AIR COOLED)  
In order to produce at full capacity, the refrigeration condenser must be kept clean. The frequency of  
cleaning will be determined by surrounding condition. A good maintenance plan calls for an inspection at  
least every two months.  
Remove the unit compartment grill at the front. With a vacuum cleaner, remove all accumulated dust and  
lint that has adhered to the finned condenser.  
CAUTION: Condenser cooling fins are sharp. Use care when cleaning.  
Publication Number: 166240010SER  
- 10 -  
© 2004, IMI Cornelius Inc.  
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Self-Contained Flaked Ice Maker Service Manual  
BK  
YL  
ON -OFF SWITCH  
CIRCUIT BREAKER  
RATED 2.0 AMPS  
GR  
WH  
BK  
WH  
BK  
BK  
BK  
BL  
BL  
GEAR  
BIN  
THERMOSTAT  
BL  
MOTOR  
WH  
GEAR MOTOR  
START CAPACITOR  
64 -77 MFD 165 VAC  
3
M
YL  
4
2
RD  
RD  
GEAR MOTOR  
START RELAY  
WH  
FAN MOTOR  
MANUAL RESET  
HIGH PRESS CNTRL  
C.O. 450 PSIG  
M
BK  
BK  
FAN SWITCH  
C.O. 205 C.I. 275  
WH  
BK  
BK  
COMPRESSOR  
OVERLOAD  
COMPRESSOR  
R
BL  
1
2
C
RD  
YL  
5
1
S
BK  
BK  
BK  
3
COMPRESSOR  
START CAPACITOR  
145 -174 MFD 220 VAC  
WH  
COMPRESSOR  
START RELAY  
BK  
CONTACTOR  
115 VOLTS 60 Hz  
AF--200--P--SC--R  
Part No. 161909061  
Artwork 50922  
FIGURE 4. WIRING DIAGRAM AF- 200-PSCR 115 VOLTS 60 HZ  
© 2004, IMI Cornelius Inc.  
- 11 -  
Publication Number: 166240010SER  
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Self-Contained Flaked Ice Maker Service Manual  
RD  
BL  
BR  
ON -OFF SWITCH  
CIRCUIT BREAKER  
LB  
GN/Y  
RATED 1.5 AMPS  
RD  
BK  
BL  
BL  
BL  
BL  
BL  
GEAR  
MOTOR  
BIN  
THERMOSTAT  
GEAR MOTOR  
START CAPACITOR  
21 -25 MFD  
RD  
3
M
YL  
220/250 VAC  
4
2
RD  
RD  
GN/Y  
GEAR MOTOR  
START RELAY  
RD  
MANUAL RESET  
HIGH PRESS CNTRL  
C.O. 450 PSIG  
FAN MOTOR  
M
BK  
BK  
FAN SWITCH  
C.O. 205 C.I. 275  
GN/Y  
BK  
RD  
BK  
BL  
COMPRESSOR  
OVERLOAD  
COMPRESSOR  
M
RD  
R
S
2
1
BK  
BR  
BK  
C
1
YL  
RD  
LB  
BK  
BL  
S
BK  
GN/Y  
COMPRESSOR  
START CAPACITOR  
50 -60 MFD 330 VAC  
RD  
COMPRESSOR  
START RELAY  
RD  
CONTACTOR  
220 VOLTS 50 Hz  
AF--200--P--SC--50--R  
Part No. 161909064  
Artwork 50929  
FIGURE 5. WIRING DIAGRAM AF200PSC50R 220 VOLTS 50 HZ  
Publication Number: 166240010SER  
- 12 -  
© 2004, IMI Cornelius Inc.  
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Self-Contained Flaked Ice Maker Service Manual  
BK  
YL  
GW  
ON -OFF SWITCH  
CIRCUIT BREAKER  
RATED 2.0 AMPS  
WH  
BK  
WH  
BL  
BK  
BL  
RD  
GEAR  
YL  
BL  
DELAY  
THERMOSTAT  
BL  
MOTOR  
M
WH  
BIN  
THERMOSTAT  
GEAR MOTOR  
START  
CAPACITOR  
3
BK  
YL  
4
2
RD  
RD  
GEAR MOTOR  
START RELAY  
RD  
BL  
BL  
M
BK  
BK  
BK  
WIRE NUT  
CONDENSOR FAN  
FAN SWITCH  
C.I. 275 C.O.205  
WH  
CONTROL  
HIGH PRESSURE  
C.O. 450 PSI  
BK  
COMPRESSOR COMPRESSOR  
OVERLOAD  
RD  
R
COMPRESSOR  
START  
C
1
S
CAPACITOR  
243 -292 MFD  
115 VAC  
BL  
RD  
BL  
YL  
OR  
BK  
2
BK  
5
CONTACTOR  
POTENTIAL  
START RELAY  
1
A F 5 2 5 -- S C -- R  
A F 7 2 5 -- S C -- R  
115 VOLTS 60 Hz  
Part No. 161909062  
Artwork 50923  
Rev.  
B
FIGURE 6. WIRING DIAGRAM AF525-SCR AND AF725SCR 115 VOLTS 60 HZ  
© 2004, IMI Cornelius Inc.  
- 13 -  
Publication Number: 166240010SER  
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Self-Contained Flaked Ice Maker Service Manual  
BK  
YL  
ON -OFF SWITCH  
CIRCUIT BREAKER  
RATED 1.5 AMPS  
GW  
LB  
BR  
RD  
BK  
BL  
YL  
GEAR MOTOR  
START RELAY  
BL  
DELAY  
BL  
GEAR  
MOTOR  
THERMOSTAT  
YL  
BIN  
THERMOSTAT  
3
GEAR MOTOR  
START  
CAPACITOR  
BK  
M
YL  
2
4
RD  
RD  
RD  
RD  
GW  
RD  
FAN MOTOR  
M
BK  
BK  
BK  
BL  
WIRE NUT  
FAN SWITCH  
CONTROL  
HIGH PRESSURE  
GW  
COMPRESSOR  
OVERLOAD  
COMPRESSOR  
RD  
R
S
1
C
COMPRESSOR  
START CAPACITOR  
43 -52 MFD 330 V  
RD  
BK  
YL  
BL  
GW  
BL  
S
RD  
BK  
L
RD  
COMPRESSOR  
START RELAY  
M
CONTACTOR  
RD  
AF/WF--525PSC--50--R  
220 VOLTS 50 Hz  
Part No. 161909063  
Artwork 50925  
Rev.  
A
FIGURE 7. WIRING DIAGRAM AF/WF525PSC50R 220 VOLTS 50 HZ  
Publication Number: 166240010SER  
- 14 -  
© 2004, IMI Cornelius Inc.  
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Self-Contained Flaked Ice Maker Service Manual  
TROUBLESHOOTING  
Trouble  
Probable Cause  
Remedy  
Unit will not run  
A. On-off switch in offposition.  
B. Defective on-off switch.  
C. Blown fuse.  
A. Turn switch to on.  
B. Check and replace.  
C. Replace fuse and check for  
cause of blown fuse.  
D. Thermostat set too warm for  
ambient.  
D. Adjust colder.  
E. Power relay contacts corroded.  
F. Defective thermostat.  
E. Check and clean.  
F. Check and replace.  
G. Check wiring.  
G. Loose electrical connection.  
H. Gearmotor overload protector  
has cut off machine.  
H. Turn switch to off then to on.  
Compressor cycles  
intermittently.  
A. Low voltage  
A. Check line voltage  
B. Dirty condenser  
B. Clean condenser  
C. Remove restriction  
D. Check and replace  
E. Check and replace  
C. Air circulation restricted  
D. Defective condenser fan motor  
E. Defective relay, overload  
protector or starting capacitor.  
F. Loose electrical connection  
F. Check wiring  
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  
C. Dirty condenser  
D. Faulty compressor  
E. Refrigerant leak  
C. Clean condenser  
D. Check and replace*  
E. Check and repair  
F. Check and replace  
F. Oring leaking at bottom of  
evaporator shell  
*NOTE: Special care must be used with R404a (HP62) charged systems using (POE) Polyolester oil.  
The refrigeration system must not be open longer than 15 min., and the appropriate drier must be  
used due to the moisture absorption properties of the POE oil.  
Unit runs but makes no  
ice.  
A. Leak in refrigerant system  
B. Moisture in system  
C. No water  
A. Check and repair  
B. Check, dehydrate and add  
drier to system  
C. Check water supply  
© 2004, IMI Cornelius Inc.  
- 15 -  
Publication Number: 166240010SER  
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Self-Contained Flaked Ice Maker Service Manual  
D. Oring leaking at bottom of  
evaporator shell  
D. Check and replace Oring  
E. Compressor not running  
A. Worn or bad float valve  
B. Float and arm assembly stuck  
E. Check and replace Oring  
A. Check and replace  
B. Check and replace  
C. Check and replace  
Water leaks.  
C. Oring leaking at bottom of  
evaporator shell  
D. Storage bin drain and tubing  
D. Check and repair  
Excessive noise or  
chattering.  
A. Mineral or scale deposits on  
inside of evaporator shell  
A. Remove and clean inside  
surfaces by immersing  
evaporator shell in ice machine  
cleaner  
B. Intermittent water supply  
B. Check inlet water line  
C. Water level in float tank too low  
C. Check and adjust water  
level  
D. Auger gearmotor end-play or  
worn bearings  
D. Repair or replace  
E. Air lock in gravity water supply  
line from float tank to evaporator  
shell  
E. Check and adjust warmer  
Machine runs with full bin  
of ice.  
A. Storage bin thermostat set too  
cold  
A. Check and adjust warmer  
B. Adjust thermowell  
B. Bin thermostat thermowell out  
of path of ice  
Unit off on reset.  
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. Check and replace  
A. Re-align  
C. Auger motor has worn  
bearings  
Unit goes off on reset.  
A. Ice chute out of alignment,  
restricted ice flow out of  
evaporator section  
B. Ice chute center separator bent  
restricting ice flow out of  
evaporator section  
B. Replace ice chute  
C. Incoming water temperature  
too cold  
C. Maintain temperature above  
50°F  
D. Bin thermostat does not shut-  
off when bin is full of ice  
D. Replace bin thermostat if  
necessary  
E. Mineral or scale deposits on  
inside of evaporator shell and  
evaporator  
E. Inspect and clean  
F. Strips loose or missing on  
inside of evaporator shell  
F. Inspect and replace  
evaporator shell if necessary  
Publication Number: 166240010SER  
- 16 -  
© 2004, IMI Cornelius Inc.  
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Self-Contained Flaked Ice Maker Service Manual  
G. Low ambient temperature in  
room where unit is located  
G. Maintain temperature above  
50°  
H. Gearmotor sticking which  
causes it to draw excessive  
amperage (over 2.0 amps)  
H. Check amp draw of  
gearmotor with an amprobe  
(1.7 amps)  
Unit goes off on reset.  
(contd)  
I. Plugged expansion valve,  
causing low back pressure  
I. Check back pressure,  
replace valve, evacuate and re-  
charge system, replace drier-  
strainer  
J. Slight leak, causing low back  
pressure  
J. Check back pressure, find  
gas leak, repair leak, evacuate  
system, add drier and recharge  
K. Loose hold-down assy  
K. Check and tighten or  
replace  
L. Auger worn excessively on the  
inside surfaces causing thicker  
flaked ice to be made  
L. Replace auger  
M. Auger out of line causing  
excessive wear on the lower  
outside surface where it rubs  
against evaporator shell liner at  
the bottom  
M. Replace auger and  
evaporator shell  
N. Broken auger  
N. Replace auger  
O. Evaporator surfaces worn or  
gouged, causing thicker ice to be  
made  
O. Inspect and replace  
evaporator if necessary  
P. Auger guide bushing worn  
down  
P. Replace auger guide  
bushing (corkscrew type  
augers only)  
Q. Loose gearmotor mounting  
plate  
Q. Check and tighten  
R. Low water level in float tank  
reservoir  
R. Adjust float arm to maintain  
correct water level  
S. Worn thrust washer  
S. Replace  
© 2004, IMI Cornelius Inc.  
- 17 -  
Publication Number: 166240010SER  
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IMI Cornelius Inc.  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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