Cornelius XWC1230 User manual

Suction Line and Service Valve Assemblies Installation Instructions

INSTALLATION INSTRUCTIONS

SUCTION LINE AND SERVICE VALVE ASSEMBLIES P/N 631500282

This kit applies to the XWC1230 Water Cooled Condenser X-Series Ice Maker

WORK OVERVIEW

1. Disconnect power. Shut off potable water and condenser water supplies.

2. Remove exterior panels. Recover refrigerant in system.

3. Disconnect electrical harnesses and remove structural panels.

4. Remove existing piping assemblies.

5. Place and braze new piping assemblies. Leak test unit.

6. Insulate critical components, replace structural panels, and reconnect electrical harnesses.

7. Turn on condenser water and potable water supply.

8. Evacuate system and recharge with refrigerant.

9. Run test unit.

10. Replace exterior panels.

Release Date: March 21, 2014 www.cornelius.com Revision: B

Suction Line and Service Valve Assemblies Installation Instructions

LOOSE-SHIPPED PARTS

Item No. Part Number Description Qty.

1 630001159 Suction Line Heat Exchange Assembly 1

2 630001160 Service Valve and Bracket Assembly 1

3 630001178 Suction Line to LH Evaporator (Extension) 1

4 163506001 Wire Tie - 7” 3

5 630900972 Insulation Tape Kit - Expansion Valve Bulb 2

6 164005001 1/8” POP Rivet - Stainless 1

Suction Line and Service Valve Assemblies Installation Instructions

GENERAL WORK GUIDELINES

• Read and understand all instructions before starting.

• Disconnect all electrical power from unit prior to beginning work.

• Shut off potable and condenser water supplies to unit prior to beginning work.

• Prepare work area so that no brazing material, dirt, metal shavings, or other objects/refuse will enter

the ice storage area.

• Save all screws, nuts, bolts, grommets, or other hardware.

• Work is to be performed by a trained, EPA certified refrigeration mechanic.

INSTRUCTIONS

1. DISCONNECT ALL ELECTRICAL POWER FROM UNIT.

2. SHUT OFF WATER SUPPLY - Potable (evaporator supply) AND Condenser supply.

3. Remove the front panel cover (a), top cover (b), and louvered side panel (c) (FIGURE 1).

4. Remove the evaporator splash panel (d) and control box cover (e) [not shown] (FIGURE 2).

5. The icemaker should be charged with 45 ounces of R-404A (HP-62). Regardless of the condition of

the refrigerant, it must be recovered (as defined in ARI Standard 740-91) from the system.

The refrigerant type and charge are indicated on the serial plate, located on the water pan

(f)(FIGURE 2).

USE ONLY RECOVERY EQUIPMENT DESIGNATED FOR USE WITH R-404A (HP-62)

REFRIGERANT.

Comply with all federal regulations concerning the handling of refrigerants.

WARNING: If the compressor has burned-out, there is a refrigerant leak, moisture is present, or

contaminates or other noncondensables are in the system, the refrigerant recovered from this

unit may NOT be reused in this product until it has been reclaimed to meet ARI Standard 700-88.

FIGURE 1 FIGURE 2

Suction Line and Service Valve Assemblies Installation Instructions

6. Drain the evaporator water pans (a)(c) by

removing the connection tube behind the

metal evaporator support (b) (FIGURE 3).

The water MUST be drained from both

RIGHT and LEFT pan. Failure to do so will

cause the pressure transducer (which

controls the harvest cycle) to be set

improperly on start up.

DO NOT drain the water into the ice

storage area, unless the area is

completely free of ice.

Replace the connection tube and metal

support when the pans are completely

drained.

NOTE: The water pump motor must be

protected from water splash. DO NOT

introduce water into the motor housing.

Warranty on water pump is VOID if water

damaged.

FIGURE 3

7. Disconnect the electrical plug from the Water Fill Valve (d) and Water Dump Valve (e) (FIGURE 4).

8. Disconnect the Water Pump plug (f) and Transducer Pressure Hose (g) (FIGURE 5).

FIGURE 4 FIGURE 5

Suction Line and Service Valve Assemblies Installation Instructions

9. Disconnect the plugs from the Hot Gas

Solenoid Valve (FIGURE 6).

Remove the compressor junction box

cover and disconnect all electrical leads

(FIGURE 7 and FIGURE 8).

Remove the ground wire from the screw

post on the chassis, by the compressor.

FIGURE 6

FIGURE 7 FIGURE 8

Yellow

Red

Black

Suction Line and Service Valve Assemblies Installation Instructions

10. Disconnect and remove the leads from the junction box (FIGURE 9) for the:

A. Curtain Switches - 2 white low voltage plug harnesses (Control board)

B. High Pressure Cutout - 2 blue wires (Contactor and #5 pin on control board)

FIGURE 9

11. Remove the 2 screws connecting the

service valve bracket (c) to the control box

(FIGURE 10).

FIGURE 10

Installation Instructions Suction Line and Service Valve Assemblies

12. Remove the 2 screws connecting the top support brace (a) to the evaporator bulkhead (FIGURE

11).

13. Drill out the rivet attaching the right side panel to the base (FIGURE 12). A 1/8”drill bit is

recommended.

FIGURE 11 FIGURE 12

14. Remove the 5 screws attaching the right side panel to the rear panel (FIGURE 13).

15. Lift and set aside the right side panel, control box, and support brace assembly (a).

16. Remove the 2 screws holding the 2 piping access covers (b) to the wrap panel (FIGURE 13).

FIGURE 13

aX5

Installation Instructions Suction Line and Service Valve Assemblies

17. Remove the bulkhead seals at the front of

the evaporator assembly.

Remove the insulation from the evaporator

inlet and outlet lines (FIGURE 14).

Remove enough insulation to safely

disconnect these lines.

WARNING: All plastic, electrical, or sensing

components, assemblies, or harnesses must

be protected when heating the refrigeration

lines.

Failure to take appropriate actions may

result in damage to the unit.

THE REFRIGERANT IN THE SYSTEM

SHOULD BE RECOVERED AND THE

SYSTEM PURGED WITH NITROGEN PRIOR

TO ANY BRAZING OPERATIONS.

Failure to take appropriate actions may

cause damage to the unit and result in

personal injury or death.

FIGURE 14

18. If the refrigerant in the system has been

fully recovered, open the high side service

valve.

Attach a nitrogen feed (a) to the low side

service valve (5-10 psi) (FIGURE 14).

Open the low side service valve to purge

the system with nitrogen.

As power to the unit has been

disconnected, disassemble the hot gas

valve to allow nitrogen to flow through the

entire system (FIGURE 15).

19. Protecting the water pump and plastic

bulkhead from heat, remove the

evaporator piping at the bulkhead

(FIGURE 14).

FIGURE 15

Ring Seal

Installation Instructions Suction Line and Service Valve Assemblies

20. Move the nitrogen feed to the high side

service valve.

21. Remove the suction line (a) from the water

cooled condenser (FIGURE 17).

DO NOT remove the water lines from the

condenser.

WARNING: DO NOT apply excessive heat to

the water side of the condenser. Protect in

the same manner as an expansion valve or

other heat sensitive equipment.

Remove the liquid line (b) from the water cooled

condenser, and the water control valve capillary

FIGURE 16

22. At the rear of the unit, remove the suction

line (d) from the left evaporator. Do not

remove the line extension (e) (FIGURE

17).

FIGURE 17

Installation Instructions Suction Line and Service Valve Assemblies

Remove the liquid line (f) AND the extension (g)

from the left evaporator. LEAVE the elbow fitting

on the evaporator (FIGURE 18).

FIGURE 18

23. Move the nitrogen feed to the low side

service valve.

24. Remove the insulation from the suction

inlet (a) to allow safe removal of the line

from the compressor (FIGURE 19)

25. Remove the suction line inlet (a) and the

compressor discharge (b) from the

compressor.

26. Remove the service valve line (c) from the

compressor.

Remove and discard the service line and

suction line assembly.

FIGURE 19

Elbow

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