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Cornelius XAC 1030 E50, Service Training Manual

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Cornelius XAC 1030 E50 Service Training Manual Download Page 1

Service / Training Manual

Revision Date:  October 17, 2005

Release Date: November 26, 2001

Publication Number: TP00952

Revision: F

www.cornelius.com

Distributed By:

Commercial Refrigeration Service, Inc.

WWW.CorneliusParts.COM

WWW.IceCubes.NET

(866) 423-6253
(623) 869-8881

for model numbers

beginning with

XAC, XWC, or XRC

Summary of Contents for XAC 1030 E50

Page 1: ...Release Date November 26 2001 Publication Number TP00952 Revision F www cornelius com Distributed By Commercial Refrigeration Service Inc WWW CorneliusParts COM WWW IceCubes NET 866 423 6253 623 869...

Page 2: ......

Page 3: ...eplate 5 Installation Instructions 6 Location of Equipment 6 Equipment Set Up 6 Dispenser Installation 7 Plumbing Connections 8 Electrical 8 Installation Check Points 8 Start Up and Check Out 8 Start...

Page 4: ...Temperature Delay 23 Possible Causes 23 High Condenser Temperature 23 Possible Causes 24 Open Condenser Thermistor 24 Possible Causes 24 Failed Water Temperature 24 Possible Causes 24 Open Water Ther...

Page 5: ...XV Product Symptoms 30 Flooding TXV Product Symptoms 30 Water Regulating Valve 31 Service Stem Valves 31 Moisture Contamination 32 Compressor Contactor 32 Compressor Starting Component Check Out Proce...

Page 6: ...s placed on the dispenser or bin Always seal the ice maker to the bin with a gasket or food grade sealant Sealing prevents melted ice from running out of the joint between the ice machines S Choose th...

Page 7: ...e model number and the serial number of your ice equipment These numbers are required when requesting information from your local dealer distributor service company Model Number Date Installed Serial...

Page 8: ...OR Amps Watts 1 7 50 NA NA 1 7 50 NA NA NA NA 1 1 75 NA NA NA NA 1 1 75 WATER PUMP Amps Watts 0 7 20 Model XWC 830 XRC 830 XAC 1030 XWC 1030 XRC 1030 XAC 1230 XWC 1230 XRC 1230 XWC 1230 E50 XAC 1444 E...

Page 9: ...P Amps Watts 0 7 20 Model XAC 630 E50 XAC 830 E50 XAC 1030 E50 XAC 1230 E50 XAC 1844 3PH XWC 1844 3PH XRC 1844 3PH XWC 522 530 E60 XWC 522 E50 XAC 522 530 E60 UNIT Volts Phase Hertz No Wires 220 1 50...

Page 10: ...for visible damage Open and inspect as required before the driver leaves and have him or her note any damage on the receipts All damaged claims must be inspected within 15 days of delivery Notify your...

Page 11: ...Should the location of your product ever be exposed to freezing temperatures it must be shut down and winterized EQUIPMENT SET UP The following steps refer to the set up of the ice bin and the cuber...

Page 12: ...Install Bin stat Part No 631500074 See Bin Stat Kit Instructions Figure 4 is an example of a typical electrical and plumbing connection AIR COOLED MODELS WATER COOLED MODELS Electrical Service Line M...

Page 13: ...box of the control box and the cuber 4 Cuber must be grounded by the control box ground screw or other method for intentional safety grounding that meets code requirements 5 A manual disconnect in a...

Page 14: ...r operator know 1 Location of electrical disconnect switch and water shut off valves 2 How to start and or shut down the product clean and sanitize it 3 Bin full operation and reset operation of high...

Page 15: ...button to start a 4 minute defrost cycle Button is located on the control board see Figure 5 FILL VALVE WATER PRESSURE LINE POWER NEUTRAL HOT GAS WATER PUMP COMPRESSOR FAN MOTOR AIR COOLED DUPM VALVE...

Page 16: ...porator The cleaner will drain into the water pan 4 Remove the water tube clean with brush and Calgon Nickel Safe ice machine cleaner 5 Return the water curtain s to their proper operating positions 6...

Page 17: ...label 3 Turn the Cuber power switch ON allowing the compressor to start Depress the clean button two times on the control board The unit will run through a 15 minute sanitizing cycle 4 Once the saniti...

Page 18: ...below if the control is replaced Model Switch 1 Switch 2 Switch 3 Proximity Switch Circuits 300 OFF OFF OFF 1 500 ON OFF OFF 1 600 800 1000 OFF ON OFF 1 1200 ON ON OFF 2 1400 1800 OFF OFF ON 2 NORMAL...

Page 19: ...start and the freeze cycle begins DUMP CYCLE 1 The dump cycle can be changed by moving the setting on the dump cycle dip switches 2 If both switches are off the machine dumps water after each cycle T...

Page 20: ...from going into a defrost cycle until the compressor has been running for a minimum of five minutes The control board revisions number are 100592 CRN 100795 CRN NOTE As ice builds on the evaporator t...

Page 21: ...t range NOTE Never judge the thickness of the ice from the first batch of the ice produced the first cycle is a balance cycle Always wait for the second cycle before making any adjustments TOTAL ICE C...

Page 22: ...D COMPRESSOR RUN CAPACITOR YL WATER FILL BK WH PUMP See note CLEAN 36430001 Processor Manufacturing Date Triac N Bin S N S YL Plug Cable Stacking Stack Out Com 1 In 2 LH Evap Switch RH Evap Switch 5 Y...

Page 23: ...contactor S Water Pump S Hot Gas Valve S Condenser Fan cycles on off with fan S Fill Valve Red S Error located on the electrical box front S Ice thickness Adjustment Refer to flash codes for control...

Page 24: ...ill Valve Green LED on Fill valve open Dump Valve Green LED on Dump valve open Ice Making Mode Green LED on or off Condenser fan cycles on and off depending upon condenser temperature Green LED on Wat...

Page 25: ...essed twice See Figure 12 Clean Button FIGURE 12 3 The hot gas valve opens 4 The microprocessor monitors the proximity switch circuits waiting for all circuits to open 5 Once all circuits have opened...

Page 26: ...me Out Delay 2 Water Fill Time Out Shut Down 3 Failed Harvest Delay 3 Failed Harvest Shut Down 4 Maximum Freeze Time Out Delay 4 Maximum Freeze Time Out Shut Down 6 Low Condenser Temperature Delay 6 L...

Page 27: ...sure tube disconnected or cut 5 Pressure sensor failure 6 Leak in water pan 7 Water pan cap removed MAXIMUM FREEZE TIME OUT 1 At the beginning of the prechill cycle the microprocessor starts a timer 2...

Page 28: ...f the microprocessor does not recognize all proximity switch circuits close 5 second after the last one opens the machine enters a delay sequence 2 The machine turns off all outputs except the bin ful...

Page 29: ...ine will not run until the power is cycled Off and On to reset the control board Possible Causes 1 Thermistor wire removed 2 Thermistor failure FAILED WATER TEMPERATURE 1 After initial start up the mi...

Page 30: ...or remote units Warning LED Error LED 1 High Condenser Temperature Warning 1 High Condenser Temp Shutdown 2 Failed Freeze Time Out Shutdown 3 Failed Harvest Shutdown 4 Low Condenser Temperature Warnin...

Page 31: ...er the hot gas valve opens the machine goes into another water fill and freeze cycle 2 If the harvest time again exceeds 4 minutes the machine goes into another water fill and freeze cycle 3 If the ha...

Page 32: ...3 Plugged condenser 4 No water flow water cooled units only OPEN CONDENSER THERMISTOR SHUTDOWN 1 If the condenser temperature thermistor is open the machine shuts down 2 While shut down the ERROR LED...

Page 33: ...l the power is cycled OFF and then ON Possible Causes 1 Water pump failure 2 Low refrigerant charge 3 Leak in refrigerant lines 4 Compressor failure 5 Hot gas valve leaking OPEN WATER TEMPERATURE THER...

Page 34: ...ximity Switch Pins and Condenser Thermistor Pins Turn Cuber power switch OFF Disconnect proximity switch plug s and condenser sensor plug from the circuit board Use a digital multimeter set for D C Vo...

Page 35: ...essure lower than normal for the operating conditions 2 Ice production lower than normal and or none 3 Ice pattern on evaporator if any thin at top and thick at bottom Flooding TXV Product Symptoms 1...

Page 36: ...harvest cycle Should the valve fail to close during the harvest mode the condenser will continue to condense the compressor discharge vapor needed for the harvest cycle and this will result in long ha...

Page 37: ...Meg Ohm would be an indicator that the system being tested may have a contamination problem Where does the problem come from As an example the filter drier may become saturated and hold large percent...

Page 38: ...n mounting Current For the current type contacts are normally open The start contacts close by the high current draw from the locked rotor condition with only the run winding in the circuit As the con...

Page 39: ...2 Refrigerant vapor is heavier than air When leak checking suspect areas probe below the joints or connections A Always check the high side of the system with the compressor operational B Check the lo...

Page 40: ...45 minutes and a remote product no less than 60 minutes The system should be evacuated to approximately 200 250 microns Then perform a 5 minute holding test You may expect a low grade loss of the vac...

Page 41: ...re that this standard is met Chemical analysis is the key requirement to the definition of Reclaim Regardless of the purity levels reached by a re processing method the refrigerant is not reclaimed un...

Page 42: ...in full D Remove ice from curtain Eliminate curtain restriction PROXIMITY SWITCH LIGHT OUT A Loose wire connection at circuit board A Tighten reattach wire B Proximity switch defective see check out p...

Page 43: ...valve failure C Pressure tube failure D Pressure sensor failure E Water leak F High or low ambient temperature B Replace as needed C Ensure that pressure tube is connected and free of cuts or kinks D...

Page 44: ...ly or leaking during harvest E Adjust water regulator valve or replace 260 to 271 PSI F Scale build up on evaporator F Clean per instructions G Hot gas solenoid valve not opening Slow rise of low side...

Page 45: ...lift FIGURE 15 NOTE Remove pump tubing from the dump solenoid after the pump has been lifted out of the res ervoir disconnect the distributor tubing at the tee fitting and lift pump out ICE WILL NOT...

Page 46: ...ES FAN MOTOR HEAT EXCHANGER FILTER DRIER COMPRESSOR LOW SIDE SERVICE VALVE REFRIGERATION AND WATER SYSTEMS MODELS XAC322 XAC330 XAC522 XAC530 XAC630 XAC830 HIGH SIDE SERVICE VALVE THERMOSTATIC EXPANSI...

Page 47: ...FILTER DRIER WATER INLET HEAT EXCHANGER PRESSURE SWITCH LOW SIDE SERVICE VALVE HIGH SIDE SERVICE VALVE COMPRESSOR Refrigeration and Water Systems Models XWC322 XWC330 XWC522 XWC530 XWC630 XWC830 THER...

Page 48: ...ort into the coiled end of capillary tube Carefully wrap 5 turns of free capillary tube tightly around the Bin Stat support Insert the assembly through the hole in the chassis base Route capillary tub...

Page 49: ...Xtreme Ice Training Manual TP00952 October 17 2005 44 COIL THERMOSTAT KIT ASY 631500074 ELECTRICAL BOX ASY TO CHASSIS BASE SCREW TC 08 32 TO CIRCUIT BOARD FIGURE 18...

Page 50: ...YL YL Manufacturing Date Processor 36430001 Micro pot 5 1 2 3 4 6 7 White Lead Condenser Sensor See note 1 Harvest Off 3 1 2 Adjust Thickness Bridge RD FILL VALVE DUMP VALVE FAN MOTOR AIR COOLED COMPR...

Page 51: ...Xtreme Ice Training Manual TP00952 October 17 2005 46 CAPILLARY TUBE BIN STAT SUPPORT SEE DETAILA DETAIL A SCALE 1 2 INSERT COIL AROUND BIN STAT SUPPORT 8 32 HEX BIN STAT SUPPORT NUT FIGURE 20...

Page 52: ...installation is complete 2 Assembly of remote condenser See the following Figures A Assemble legs to base panel Install leg supports on legs B Locate the remote condenser in a well ventilated area on...

Page 53: ...IMI Cornelius remote condens er and line set may be reason to void the cuber warranty LIQUID REFRIGERANT LINE DISCHARGE LINE CORRECT FIGURE 23 4 Each condenser and cuber is connected with two 2 pre c...

Page 54: ...ollowing calculations should be made NOTE Max line set for IMI Cornelius cubers is 55 ft Do not confuse line length with calculated line distance A RISE CONDENSER HIGHER THAN EVAP MAX 35 FT B LINE LEN...

Page 55: ...S WITH HORIZONTAL FIGURE 27 CAUTION If a line set rise is followed by a line set drop a second line set rise cannot be made Or If a line set drop is followed by a line set rise a second line set drop...

Page 56: ...des 6 Start Up A Use standard procedures from cuber installation instructions B After the cuber is running check the remote condenser and verify that the condenser fan is run ning CAUTION Once the ref...

Page 57: ...nd correct as required If adding refrigerant does not correct continued bypass condition and line set is not damaged replace headmaster REMOTE SYSTEM EVACUATION RE CHARGE All field repairs to the seal...

Page 58: ...N VACUUM PUMP ELECTRONIC SCALE CHARGING CYLINDER CLOSED CLOSED LOW SIDE SERVICE VALVE HIGH SIDE SERVICE VALVE OPEN OPEN 1ST STAGE CHARGING MANIFOLD SET OPEN RECEIVER OPEN RECEIVER OUTLET VALVE OPEN VA...

Page 59: ...Xtreme Ice Training Manual TP00952 October 17 2005 54 THIS PAGE LEFT BLANK INTENTIONALLY...

Page 60: ...17 2005 55 IMI CORNELIUS INC CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 763 421 6120 800 238 3600 Distributed By Commercial Refrigeration Service Inc WWW CorneliusParts COM...

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