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Service Manual

Release Date: February 16, 2012

Publication Number: 621058426SER

Revision Date: N/A

Revision: A

Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

Summary of Contents for signature

Page 1: ...SIGNATURE Service Manual Release Date February 16 2012 Publication Number 621058426SER Revision Date N A Revision A Visit the IMI Cornelius web site at www cornelius com for all your Literature needs...

Page 2: ...ervice 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 service conditions with respect to the P...

Page 3: ...trol Panel 4 Control Panel Display 5 Control Panel Button Descriptions 5 Controls and Indicators 5 ON OFF Button 5 FREEZE Button 5 CLEAN Button 6 REFRIGERATE Button 6 Program Settings 6 Programming Mo...

Page 4: ...on 30 Component Remote Control 31 Paddle Motor Replacement 32 Condenser Fan Motor Replacement 33 Compressor Replacement 35 Liquid Line Solenoid Valve Replacement 36 High Pressure Switch Replacement 37...

Page 5: ...ation which if not avoided COULD result in serious injury death or equipment damage CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or e...

Page 6: ...tion observe the following WARNING Disconnect power to the unit before servicing following all lock out tag out proce dures established by the user Verify all of the power is off to the unit before an...

Page 7: ...r 621058426SER MOUNTING ON A COUNTER WARNING When installing the unit on a counter top the counter must be able to support a weight in excess of 300 lbs to insure adequate support for the unit FAILURE...

Page 8: ...in design and has built in features and diagnostic controls to help the service technician quickly and accurately maintain and service the unit The unit consists of a freeze barrel that contains an i...

Page 9: ...escribed in Table 2 on page 9 CONTROLS AND INDICATORS ON OFF Button The ON OFF Button toggles access between the operational modes and the pro gramming service modes When the ON OFF Button is pressed...

Page 10: ...the Programming Mode repeatedly pressing the CLEAN Button steps through the possible fine viscosity level settings for the product In the Component Remote Control Mode the CLEAN Button is used as an...

Page 11: ...the FREEZE Button repeatedly steps through the available motor types Component Remote Control Mode This mode accessed by pressing the REFRIG ERATE Button in the Service mode allows the technician to...

Page 12: ...r the viscosity desired There are twenty one levels of viscosity 3 coarse settings and 7 fine settings available for the Signa ture unit Figure 2 shows how the three coarse and seven fine levels are d...

Page 13: ...eplate switch is deac tivated Motor power is not available also see next error The unit is disabled until the faceplate is properly installed 6 FL1 L3 AC Relay Open This error occurs when the motor co...

Page 14: ...if voltage is reestablished within normal limits for at least 30 sec User can clear the error from the front panel by pressing and holding the ON OFF Button for 3 seconds 14 FL3 Motor Stall This erro...

Page 15: ...arrel to fill with product and insert the air mix tube into the bowl if dairy product is being used 3 Press the ON OFF Button on the control panel to activate the control panel 4 Press the FREEZE Butt...

Page 16: ...oft cloth CAUTION Avoid the use of abrasive cleaners and chlorine based solutions which can damage the finish If desired small parts may be cleaned in a dishwasher Cleaning and Sanitizing Procedure Un...

Page 17: ...he ON OFF Button to turn the unit ON and push the CLEAN Button 4 Place an empty bucket under the Product Dispense Valve and move dispense handle to the right open position shown in Figure 4 and drain...

Page 18: ...rocedure 1 Remove Bowl Lid Cover 2 Prepare detergent water by mixing 3 0 oz 89 ml of a dish washing deter gent in 3 0 gallons 11 4 liters of 90 to 100o F 32 to 38o C warm water 3 Pour the detergent so...

Page 19: ...ulling it out the top of the Faceplate See Figure 11 7 Carefully remove the two 2 O Rings from their grooves and slide them to the narrow area of the Plunger See Figure 10 TIP Use a paper towel to squ...

Page 20: ...4 Figure 13 S SC CR RA AP PE ER R B BL LA AD DE E A AU UG GE ER R S SC CR RA AP PE ER R B BL LA AD DE E 1 1 2 2 4 4 3 3 5 5 8 8 6 6 7 7 G GA AS SK KE ET T C CR RO OS SS S P PA AT TT TE ER RN N P PR RO...

Page 21: ...100o F 32 to 38o C warm water 2 Place all parts in detergent solution and thoroughly wash each part that has been removed in System Disassembly and the Air Tube Thoroughly brush clean all disassembled...

Page 22: ...ign it so the Han dle can be inserted into the Plunger through the Faceplate as shown in Figure 21 Push in and rotate the Handle until it snaps into place 4 Reassemble the Auger Drive Magnet by pressi...

Page 23: ...n top of the unit 10 Replace the Mixing Blades and Blade Sweepers for dairy products into the Product Bowl and place the Bowl Lid Cover onto the Product Bowl 11 Replace the Drip Tray and Cup Rest as s...

Page 24: ...solution Figure 26 Figure 27 Figure 28 Figure 29 Figure 25 F FA AC CE E P PL LA AT TE E K KN NO OB BS S C Cu up p R Re es st t D Dr riip p T Tr ra ay y 1 1 2 2 4 4 3 3 5 5 8 8 6 6 7 7 G GA AS SK KE E...

Page 25: ...uct to drain until sanitizer solution exits the valve 10 Remove the Bowl Lid Cover 11 Using a clean bucket pour 3 0 gallons 11 4 liters of potable water into the Product Bowl 12 Replace the Bowl Lid...

Page 26: ...when noticed 10 620054997 O Ring 2 11 620042994 Knob 4 12 620043383 Handle Dispensing 1 13 620047944 Auger 1 14 620049764 Drive Magnet Assembly 1 14A 620046135 Coupling 1 14B 560004289 Bearing 1 15 6...

Page 27: ...e several procedures that should be completed on a semi annual basis These procedures help to insure proper operation of the system on a long term Table 13 Step Procedure 1 Turn off the unit 2 Reach u...

Page 28: ...page 16 4 Wipe out the barrel with a clean damp soft cloth 5 Inspect the Scraper Blades for wear and replace if necessary 6 Assemble the Scraper Blades on the auger and insert it into the barrel whil...

Page 29: ...type calibrate the barrel motor and to manually control the loads in the system motors valves compressor To enter the Service Mode press and hold the CLEAN and REFRIGERATE Buttons simultaneously for m...

Page 30: ...ronic components from any static dis charge while working on the unit The Control board is located on the left side of the unit It is mounted to a panel on five 5 plastic mounting posts shown in Figur...

Page 31: ...and lifting cover off the two tabs at the top as shown in Figure 36 5 Unplug all of the connectors from the board 6 Pop the board off the mounting posts See Figure 37 7 Replace the board 8 Reconnect...

Page 32: ...ore performing any work Failure to comply could result in serious injury death or damage to the equipment The barrel motor assembly consists of the motor and magnet assembly If this assem bly must be...

Page 33: ...agnet as shown in Figure 41 10 Loosen the set screw on the side of the magnet collar as shown in Figure 42 11 Remove the magnet from the motor shaft 12 Remove the four 4 mounting bolts and bracket fro...

Page 34: ...Bracket Motor Calibration Motor calibration is required whenever a motor or any components in the barrel drive system are replaced or magnetic drive components are replaced Perform the proce dure in...

Page 35: ...LEAN Button becomes an ON OFF Button for the load and the FREEZE Button has no functionality There is a seven second automatic time out on all loads Figure 44 Remote Control Status LEDs 2 From the Ser...

Page 36: ...e 36 6 Disconnect the paddle motor by disconnecting the motor leads from the connec tors located near the control board on the left side of the unit shown in Figure 45 7 Remove the two screws holding...

Page 37: ...otor Location CONDENSER FAN MOTOR REPLACEMENT The fan motor is located in the rear of the unit as shown in Figure 48 If the motor needs replacement perform the procedure in Table 20 to remove and rein...

Page 38: ...ting screws securing the fan shroud on the left side as shown in Figure 50 6 Remove the fan shroud from the unit 7 Pull the motor power wire through the machine grommets 8 Remove the four screws under...

Page 39: ...ng Bolts Rear of Unit Table 21 Step Procedure 1 Disconnect power to the unit 2 Remove the side panels from the unit 3 Label and disconnect all wires from the compressor 4 Reclaim the refrigerant from...

Page 40: ...the right side panel from the unit 3 Unplug the connector from the solenoid being replaced 4 Remove the two mounting screws holding the solenoid to the mounting bracket See Figure 52 5 Disconnect the...

Page 41: ...Table 24 Step Procedure 1 Disconnect power from the unit 2 Remove the side panels from the unit 3 Remove the protective cover from the control board by loosening the mounting screws from each side of...

Page 42: ...rayed or damaged the following procedures may be used to replace the cord Perform the procedure in Table 26 and refer to Figure 55 for 120VAC units This procedure should only be performed by qualified...

Page 43: ...3 Disconnect the AC and Ground connections to the E Box terminals See Fig ure 55 4 Remove the strain relief and route the cable down through the unit 5 Replace the cable with new wiring be sure strain...

Page 44: ...lter See Figure 57 4 Compress the spring tabs on the top and bottom of the filter and push it out the rear of the unit 5 Install the new filter through the rear of the unit 6 Connect the wires back to...

Page 45: ...ompressor Contactor Start Run Capacitors Compressor Step Down Transformer Hi Volt 24VAC 24 VAC Term Board Compressor Relay High Voltage Term Board Table 29 Step Procedure 1 Disconnect power from the u...

Page 46: ...ress the keypad into place on the bezel Make sure the keypad is properly aligned with the bezel before pressing it into place 9 Connect the ribbon cable to the control board 10 Re install the control...

Page 47: ...60 Thermistor Locations 9 If insulation was removed make sure it is replaced properly 10 Reconnect the thermistor to the proper connector 11 Replace the left side panel 12 Reconnect power to the unit...

Page 48: ...C Bad contactor A Check connections at contactor and fan and correct B Replace C Replace No compressor but con denser fan runs A Bad connections B Bad start relay C Bad capacitor s D Bad compressor E...

Page 49: ...ting E Defective compressor A Repair leak and weigh in new charge B Clean or repair C Repair or replace D Check cables and connections to con trol board and repair or replace E Repair or replace Restr...

Page 50: ...RG WH WH BLK BLU BLU WH BLK VIO 1 RED RED FACEPLATE PRESENCE REFRIGERANT OVER PRESSURE EXPANSION PORT J3 YEL YEL 24VAC GRN YEL BLK WH A2 A1 14 6T3 4T2 2T1 CONTACTOR COMPRESSOR CONDENSER FAN START CAP...

Page 51: ...frigeration Diagram CONDENSER Dryer ACCUMULATOR Pressure Low Side Pressure High Side Cap Tube Suction Line Heat Exchanger Liquid Solenoid Solenoid Liquid TXV EPR Valve BOWL EVAPORATOR BARREL EVAPORATO...

Page 52: ...top of the Bowl Cover including 4 in legs 35 in 89 cm Clearance required for product fill Open to ceiling additional 12 in 30 cm Width 15 1 2 in 39 cm Depth including drip tray 34 in 86 cm Operating...

Page 53: ......

Page 54: ...IMI Cornelius Inc www cornelius com...

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