Cornelius CCM0830 - Manual

General Information Page A4 Electrical and Mechanical Specifications, “CCM/CCU” Series Model Ref. Type Charge Ounces Back Press. Approx. Head Press. Approx. Timer Initiate Setting Cycle Time Approx. Minutes 70/50-90/70 Batch Weight Pounds Volt. Cycle Phase CCU0150A1 R-404a 12 60 - 47 205-400 47 24 -...

General Information Page A5 Electrical and Mechanical Specifications, “CCM/CCU” Series Model Ref. Type Charge Ounces Back Press. Approx. Head Press. Approx. Timer Initiate Setting Cycle Time Approx. Minutes 70/50-90/70 Batch Weight Pounds Volt. Cycle Phase CCM2148W2 1 R-404a 44 48 - 46 250 34 11 - 1...

General Information Page A6 Installation Guidelines 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,...

General Information Page A7 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.

General Information Page A8 Electrical and Plumbing Requirements: CCU0300 00 Note: The CCU0300 does not have a splash curtain. This model utilize a thermostatic bin control in place of a mechanical bin switch.

General Information Page A9 Electrical and Plumbing Requirements: CCM0330, CCM0430, CCM0530, CCM0630, CCM0830 and CCM1030 (30 Inch Wide Cubers)

General Information Page A13 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...

General Information Page A14 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 Remote Condenser...

General Information Page A15 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 a...

General Information Page A16 Undercounter Bin Removal-CCU0300 Series The storage bin can be removed by: 1 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. Di...

Scheduled Maintenance Page B1 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 rep...

Scheduled Maintenance Page B2 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” posi...

Winterizing Procedures Page B3 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(...

Cabinet Care Page B4 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 f...

Troubleshooting Trees Page C1 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...

Troubleshooting Trees Page C2 Troubleshooting Trees Table Of Contents Machine Does Not Run C3 Machine Runs, Does Not Make Ice C4 – C5 Slow Production (Cube Formation Good) C6 Low Suction Pressure C7 High Suction Pressure C8 Cubes Are Hollow C9 Uneven Bridge Thickness C10 Ice Bridge Thickness Varies ...

Troubleshooting Trees Page C3 Machine Does Not Run Check for correct power supply to the machine YES NOT OK NO OK Is the selector switch set to ICE ? Check High Pressure Safety Control Check High Temperature Safety Control OK Check Bin Control for proper adjustment, see page F9 Is this a Remote unit...

Troubleshooting Trees Page C4 Machine Runs, Does Not Make Ice YES GO TO PAGE C5 NO YES Is water running over the evaporator? Check for power to the compressor contactor coil Check contactor for bad contactor or coil. Replace if defective Is the compressor running? NO GOOD OK Check Selector Switch, R...

Troubleshooting Trees Page C5 Machine Runs, Does Not Make Ice (continued) HIGH OR NORMAL SUCTION Check refrigerant pressures, see page E1 If head pressure is also high, make sure Condenser is clean and machine has good air flow Is water leaking out of the Purge Drain or Water Trough? NO YES OK LOW S...

Troubleshooting Trees Page C6 Slow Production (Cube Formation Good) NO YES Does installation meet guidelines? Check refrigeration system, Section E Check for excessive head pressure OK Check Water Regulating Valve, See page E2 Check refrigeration system, Section E AIR YES TOO HIGH Clean Condenser an...

Troubleshooting Trees Page C7 Low Suction Pressure NO YES Does installation meet guidelines? Check TXV for moisture based restriction Check for correct head pressure, see page E10 NO Check for refrigerant tubing restriction, crimps, etc. Check Evaporator coil separation, see page E4 YES YES Go to Tr...

Troubleshooting Trees Page C8 High Suction Pressure NO YES Have you checked the “Slow Production” Tree? Evacuate and recharge system Check Hot Gas Valve, see page E5 NO Check for leaking Purge valve Check Condenser Fan Motor and Blade for proper operation, and/or Water Valve or Mixing Valve YES YES ...

Troubleshooting Trees Page C9 Cubes Are Hollow YES Is the water temperature above 100°F (38°C)? Go to the “Poor Water Distribution Over Evaporator” Troubleshooting Tree, page C13 NO YES YES Purge Valve has an obstruction or could be defective Is water leaking from the Purge Drain? NO NOT OK Is there...

Water System Page D1 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. During the freeze cycle water is con...

Water System Page D2 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 t...

Water System Page D3 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 t...

Water System Page D4 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-ener...

Water System Page D5 Water Trough The water trough can be easily removed by the following procedures: Mounting Screws CCU0150/0220 Models 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 m...

Refrigeration System Page E1 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 weighe...

Refrigeration System Page E2 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...

Refrigeration System Page E3 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 ab...

Refrigeration System Page E4 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 recommen...

Refrigeration System Page E5 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 evaporato...

Refrigeration System Page E6 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 clea...

Refrigeration System Page E7 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 ...

Refrigeration System Page E8 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 ...

Refrigeration System Page E9 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...

Refrigeration System Page E11 60 CYCLE and 3 PHASE 24 Hour Capacity Wires Max Min. Voltage @ 90/70 Including Fuse Circuit Comp. **Refrigerant Model Hz/Phase Lbs. Kg. BTUH Ground Size Amps RLA Type Oz. Grams CCM1448A2 208-230/60/1 1122 510 22590 3 30 20.2 13.8 R404A 104 2948 CCM1448W2 208-230/60/1 11...

Refrigeration System Page E20 CCM1030R Ambients Refrigeration Pressures PSIG Compressor Temps °F Cycle Times °F Discharge Suction Discharge Suction Minutes' Seconds" Air/Water Start End Start Freeze End Freeze Start Harv End Harv Start End Start End Freeze Harvest Complete -20/40 240 240 61 33 9...

Electrical System Page F1 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 ...

Electrical System Page F2 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...

Electrical System Page F3 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 ...

Electrical System Page F4 Timed Freeze When the freeze timer is energized, the machine is in the timed portion of the freeze cycle. The freeze timer will time out the remainder of the freeze cycle. Once the time has passed, the machine will enter the harvest cycle. Freeze Timer The freeze time is an...

Electrical System Page F5 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...

Electrical System Page F6 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 clu...

Electrical System Page F7 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. The tip of the ...

Electrical System Page F8 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...

Electrical System Page F9 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 therm...

Electrical System Page F11 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...

Electrical System Page F12 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 ...

Wiring Diagram Page G1 CCU0150/220 Air and Water Wiring Diagram includes 230 Volt and 50 Cycle

Wiring Diagram Page G2 CCU0150/220 Air and Water Wiring Schematic Includes 230 Volt and 50 Cycle

Wiring Diagram Page G3 CCM0830/CCM1030 Air and Water Wiring Diagram Includes 50 Cycle

Wiring Diagram Page G4 CCM0830/CCM1030 Air and Water Wiring Schematic Includes 50 Cycle

Wiring Diagram Page G5 CCM0830/CCM1030 Remote Wiring Diagram Includes 50 Cycle

Wiring Diagram Page G6 CCM0830/CCM1030 Remote Wiring Schematic Includes 50 Cycle

Wiring Diagram Page G7 CCM1030, 3 Phase, Air and Water Wiring Diagram

Wiring Diagram Page G8 CCM1030, 3 Phase, Air and Water Wiring Schematic

Wiring Diagram Page G9 CCM1030, 3 Phase, Remote Wiring Diagram