IMI Cornelius, Inc. COR35VMSD User manual

VISUAL MERCHANDISERS

COR7VM, COR12VM, COR17VM, COR23VM,

COR35VMSD, COR45VMSD, COR49VMD, COR67VMST

Service Manual

Release Date: May 24, 2005

Publication Number: 630460243SER

Revision Date: NA

Revision: A

Visit the IMI Cornelius web site at www.cornelius.com

for all your Literature needs.

®

SERVICE MANUAL

The products, technical information, and instructions contained in this manual are subject

to change without notice. These instructions are not intended to cover all details or varia-

tions of the equipment, nor to provide for every possible contingency in the installation,

operation or maintenance of this equipment. This manual assumes that the person(s)

working on the equipment have been trained and are skilled in working with electrical,

plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety

precautions are taken and that all local safety and construction requirements are being

met, in addition to the information contained in this manual.

To inquire about current revisions of this and other documentation or for assistance with

any Cornelius product contact:

www.cornelius.com

800-238-3600

Trademarks and copyrights:

Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olym-

pus, and Vista are registered trademarks of IMI Cornelius Inc.

Optifill trademark is pending.

This document contains proprietary information and it may not be

reproduced in any way without permission from Cornelius.

Printed in U.S.A.

Visual Merchandiser Service Manual

TABLE OF CONTENTS

Features of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Cleaning and Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Fluorescent Lamp and Ballast Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

To remove the motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Ballast Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Required tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

To remove the ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

To replace the fluorescent lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Temperature Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Required tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

To remove the temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Evaporator Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

To disconnect the evaporator fan motor electrical terminals . . . . . . . . . . . . . . . 10

To remove the evaporator fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Condensing Unit Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

To remove the motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

To pull out the condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

To replace the condensing unit fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Starting Relay, Overload Protector, and Start Capacitor Replacement . . . . . . . . . 17

Required tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

To remove the motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

To pull out the condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

To remove the electrical box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

To replace the relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

To replace the overload protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

To replace the starting capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

To install the electrical box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Door and Spring Hinge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

To remove the motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

To remove the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

To install the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

To assemble spring hinge components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Glass Door Pane Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To remove the motor cover and door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To remove the glass door pane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To install the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Starter relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Visual Merchandiser Service Manual

Thermal protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Condenser fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Evaporator fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Capillary tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Cooling cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

The Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Wiring Diagram 115 V/60 Hz/1 Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Possible causes and solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Visual Merchandiser Service Manual

FEATURES OF THE UNIT

CLEANING AND PREVENTIVE MAINTENANCE

Weekly or sooner, as required:

1. Disconnect the power source before cleaning. Remove all products and place in a proper cooler.

2. Clean the interior and exterior with a mild soap or detergent solution and then rinse with a warm

baking soda solution (one cup of baking soda to one gallon of warm water). Dry the interior

completely before replacing products.

3. Clean the condenser unit periodically by vacuuming the unit compartment, especially the

condenser unit coil (it looks like a small auto radiator). If the condenser coil has accumulated dirt

and grease (possible in heavy traffic areas or a kitchen), use a strong cleaning solution. If you find

any oil in the condensing unit compartment, call a qualified service person immediately.

4. Empty out and clean the drain pan located next to the condensing unit as required. Check regularly

for excessive water accumulation.

5. Plug in the cabinet and wait until the proper temperature is achieved before reloading the cabinet

with product.

FIGURE 1

Fluorescent interior light

Strong body with 1 3/4”

thick walls, injected with

CFC-free polyurethane

foam

Forced-air evaporator

for quick temperature

pull down

NSF compliant

interior cabinet

Heavy duty R-134a

condensing unit with zero

maintenance condenser

Heavy duty hinges

Double-pane low-e glass

door for high ambient

conditions

Durable PVC frame

Exterior cabinet made of

galvanized, pre-painted

steel, with baked polyester

paint

Reinforced heavy-duty

shelves

Reinforced, 16-gauge,

galvanized steel base

Visual Merchandiser Service Manual

FLUORESCENT LAMP AND BALLAST REPLACEMENT

If any electrical problems arise, a wiring diagram is included with each cabinet to aid in tracing the source

of trouble and making the necessary repairs.

To remove the motor cover

3. Remove the condensing unit motor cover by pulling it up and out.

CAUTION - Make sure the power supply is

turned off before making any electrical

repairs.

1. Open the door.

FIGURE 2

2. Use a #2 Phillips screwdriver to remove the flat-head screw

holding condensing the unit motor cover.

FIGURE 3

FIGURE 4

Visual Merchandiser Service Manual

BALLAST REPLACEMENT

Required tool

• one #2 Phillips screwdriver with a 4” long blade

To remove the ballast

1. Push down with your fingers on the plastic tabs that hold the male and female connectors in

position. Then pull out the male connector (connected to the ballast).

2. Use a Phillips screwdriver to remove the single screw holding the ballast to the metal bracket. The

ballast sits on a metal bracket to make replacement easier.

FIGURE 5

FIGURE 6

Visual Merchandiser Service Manual

3. To remove the ballast, lift the ballast wires over the metal bracket which holds the back end of the

ballast.

4. To reinstall a new ballast reverse steps 1 through 3.

To replace the fluorescent lamp

FIGURE 7

1. Pull one end of the lamp holder base half way out.

FIGURE 8

2. Pull the other end of the lamp holder base half way out.

FIGURE 9

Visual Merchandiser Service Manual

4. Remove the lamp holder bases from each end of the lamp.

6. To install a new lamp, reverse steps 1 through 5.

3. Once the two bases have been pulled half way out, use both

hands to pull out the entire lamp assembly

FIGURE 10

FIGURE 11

5. Remove the plastic cover from the lamp. Now you can

replace the lamp.

FIGURE 12

Visual Merchandiser Service Manual

TEMPERATURE CONTROL REPLACEMENT

If any electrical problems arise, a wiring diagram is included with each cabinet to aid in tracing the source

of trouble and making the necessary repairs.

Required tool

• one #2 Phillips screwdriver with a 4” long blade

To remove the temperature control

With the temperature control mounting plate removed from the baffle, you can see the thermostat,

light, and fan motor connectors.

CAUTION - Make sure the power supply is

turned off before making any electrical

repairs.

1. Remove the two Phillips head screws that hold the

temperature control mounting plate (located on the baffle).

FIGURE 13

FIGURE 14

Evaporator fan motor connections

Fluorescent lamp connections

Temperature control connections

Visual Merchandiser Service Manual

3. Carefully pull the bulb sensor out of the temperature control well. There is a patch of permagum at

the opening of the well which seals the bulb sensor from humidity.

2. Disconnect the electrical connections from the temperature

control.

FIGURE 15

FIGURE 16

Temperature control sensing bulb

Temperature control well

Visual Merchandiser Service Manual

The bulb sensor has a slight curve to make a tight fit inside

the temperature control well.

FIGURE 17

4. Remove the temperature control knob by pulling it outward.

FIGURE 18

5. Use a Phillips screwdriver to remove the two Phillips head

screws the hold the temperature control to its mounting

plate.

FIGURE 19

Visual Merchandiser Service Manual

EVAPORATOR FAN MOTOR REPLACEMENT

If any electrical problems arise, a wiring diagram is included with each cabinet to aid in tracing the source

of trouble and making the necessary repairs.

Required tools

To replace the evaporator fan motor, you need:

• one #2 Phillips screwdriver with 4” blade

• one side-cutting pliers

• one 1/4” socket screwdriver

6. With the two Phillips head screws removed, you can now

install a new temperature control by reversing steps 1

through 5.

FIGURE 20

CAUTION - Make sure the power supply is

turned off before making any electrical

repairs.

Visual Merchandiser Service Manual

To disconnect the evaporator fan motor electrical terminals

With the temperature control mounting plate removed from the baffle, you can see the thermostat, light,

and fan motor connectors.

1. Remove the two Phillips head screws that hold the

temperature control mounting plate (located on the baffle).

FIGURE 21

FIGURE 22

2. Disconnect the fan motor electrical connector.

FIGURE 23

Evaporator fan motor connections

Fluorescent lamp connections

Temperature control connections

Visual Merchandiser Service Manual

3. Remove the rubber grommet, located in the plastic bushing near at the right air diffuser.

To remove the evaporator fan motor

FIGURE 24

1. Use a Phillips screwdriver to remove the four screws holding

the evaporator fan grill at the baffle.

FIGURE 25

2. Remove the fan blade. Use the side-cutting pliers to

unscrew the nut-type washer that holds the fan motor in

place.

FIGURE 26

Visual Merchandiser Service Manual

3. Pass the electrical wire of the motor through the plastic bushing on the air diffuser.

6. Replace the fan motor with another of the same model. Reinstall the fan motor by reversing steps 1

through 5.

FIGURE 27

4. Use a Phillips screwdriver to remove the four screws holding the base of the fan motor to the top of

the internal cabinet.

FIGURE 28

5. Use a 1/4” socket screwdriver to remove the three socket head screws holding the fan motor to its

base.

FIGURE 29

Plastic bushing on the air diffuser

Four Phillips head screws

Three socket head screws

Visual Merchandiser Service Manual

CONDENSING UNIT FAN MOTOR REPLACEMENT

If any electrical problems arise, a wiring diagram is included with each cabinet to aid in tracing the source

of trouble and making the necessary repairs.

Required tools

The following tools are required to repair the spring hinge system or assemble a new door:

• one Phillips #2 screwdriver with 4” blade

• one 3/8” open end or box end wrench

• one 7/16” open end or box end wrench

• one adjustable wrench, 4” or 6”

• one measuring tape

To remove the motor cover

CAUTION - Make sure the power supply is

turned off before making any electrical

repairs.

1. Open the door.

FIGURE 30

2. Use a #2 Phillips screwdriver to remove the flat-head screw

holding condensing the unit motor cover.

FIGURE 31

Visual Merchandiser Service Manual

3. Remove the condensing unit motor cover by pulling it up and out.

To pull out the condensing unit

1. Use a 1/2” open or box end wrench to remove the bolts that hold the rails that support the

condensing unit.

FIGURE 32

FIGURE 33

2. Slowly push the condensing unit from the rear of the cabinet. Be sure the suction line and the

capillary tubing do not break.

FIGURE 34

Visual Merchandiser Service Manual

3. Pull the condensing unit about 13 inches from the base of the cabinet to provide access to the

condensing unit fan motor, relay, overload protector, and capacitor.

To replace the condensing unit fan motor

2. Disconnect the fan motor electrical connectors.

FIGURE 35

1. Untie the fan motor electrical wire.

FIGURE 36

FIGURE 37

Visual Merchandiser Service Manual

6. Use the side cutting pliers to remove the fan blade.

3. Use a 7/16” open end or box end wrench to remove the four

nuts and bolts that hold the base of the fan motor to the rails

of the condensing unit.

FIGURE 38

4. Tilt the fan motor from one corner in the direction of the

arrow to remove the fan motor from the condenser shroud.

FIGURE 39

5. Pull the fan motor out in the direction of the arrow.

FIGURE 40

FIGURE 41

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