F-500BAF/-C Service Manual
Contents
1. w ae 15 S Q2 15 S N N 13 N SS ofp Rho SKe SIN wlln Note The data without marks should be used for reference We reserve the right to make changes in specifications and design without prior notice 25 IV Service Diagnosis 1 No Ice Production PROBLEM POSSIBLE CAUSE REMEDY The icemaker will not start a Power Supply OFF position Move to ON position 2 Loose connection 2 Tighten 3 contacts 3 Check for continuity and replace 4 Blown fuse 4 Replace b Power Switch Off position Move to ON position Control Box 2 Bad contacts Check for continuity and replace c Fuse Control Box Blown out Check for short circuit and replace d Circuit Protect Relay Miswiring Check power supply voltage and wire properly e Flush Switch FLUSH position Move to ICE position 2 Badcontacts Check for continuity and replace Coil winding opened 1 Replace 2 Control Water Valve Coil winding opened 1 Replace h Shut off Valve Closed Open 2 Water failure till water is supplied Plug and Receptacle Disconnected Connect Control Box 2 Terminal out of Plug 2 Insert terminal back in or Receptacle position Wa2. E 29 eSa A 30 V Removal and Replacement of Components 2 een 31 Te Service Tor Refrigerant NES 31 la Retigerant 2 e t T 31 b Evacuation and Recharge R 404A 31 2 BAZIN NN TUM 32 Removal and Replacement of 33 4 Removal and Replacement ol Drier 34 5 Removal and Replacement of Expansion 35 6 Removal and Replacement of Evaporator Assembly 36 7 Removal and Replacement of Fan 22 0 04400 40 8 Removal and Replacement of Control Water Valve 40 Cleaning and Maintenance 1 Preparing the Tesmaker tor Long Storage ERE pr ek ER aste 41 2 Cleaning and Sanitizing Instructions IU EIDEM 42 l Cleaning 42 6 REOS 42 c Sanitizing o LM 43 d Sanitizing Procedure n3 ien REA RF 44 e Sanitizing Procedure Final 44 3 Maintenance
3. PROTECTOR Baan K CIRCUIT PROTECT RELAY 5 1 2 GEARMOTOR 3 4 PROTECT RELAY Jo X4 5 6 7 8 lt lt O CIRCUIT THERMAL GEAR CAP SWITCH PROTECTOR MOTOR 10MFD KR 4 0 Y V GY BK KA DBU CONDENSER FAN MOTOR Kg Ki 089 W SWITCH BK 0 WIRE COLOR CODE 0 0 W BR BROWN w WHITE TRANS Dm G 4 5R BK BLACK 97000070 3 R RED ek 24 929 R 0 ORANGE FUSE 1A 7 2 3 4 6 10 17 GY GRAY FLUSH WATER 501 4 0 DBU DARK BLUE Kg R BK V GY V VIOLET 7 LBU Euh 4 CONTROL Y YELLOW K VALVE LBU LIGHTBLUE j BU BLUE 1 2 Ki 4 R 3 4 PR Kg BU Oo HO gt FLUSH RELAY X6 P 5 6 289 an ox Oem 7 8 FLUSH oJ BEIC K SWITCH FLOAT SWITCH 0 WATER CONTROL RELAY BIN CONTROL SWITCH 0 500 20 4 Timing Chart Miswiring Circuit Protect Relay operates Proper wiring The unit starts BIN CONTROL CIRCUIT PROTECT ON 2 WATER LEVEL i FLOAT
4. ES POO BAI 5 6 l General 7 TS OMS LIC TION TETTE EUROS 7 500 om 7 2ce Making a 8 3 G ntrol BOX LAY OU RARE SAA 9 F SOUBAEP P SUDBARSD EE E 9 timer Board O O O 10 al SOlG SiatS Control C aa Caucaso Ca Cac a Cau 10 Timer BONG RR m e m 10 E E E 11 Ill mation Merc 14 T Water Circuit Refrigerant 14 F 500BAF F 500BAF G 14 T TT 15 5 0 o 15 Electrical Circuit ub aqua 16 P SO0 BAR astu p 16 4 MINY CNA eaire c 21 5 Performance anaapa qud oput EEE EEA E 24 F 500BAF EEEE AA EE EEEE EERENS 24 PSB OOD AP ernaar ae a a E A A E 25 IV Service ACN T 26 TING ICS PIG GUGM 26 2 Low
5. EXTERIOR FINISH PVC Coated Galvanized Steel Galvanized Steel Rean Stainless Steel WEIGHT Net 210 Ibs 95 kg Shipping 245 Ibs 111 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Drain Pan 3 4 FPT Bin Drain 3 4 FPT ICE MAKING S YS TEM Auger type HARVES TING SYSTEM Direct Driven Auger 1 6 HP Gear Motor ICE MAKING WATER CONTROL Float S witch COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Bin Control P roximity S w COMPRESSOR Hermetic Model RS 43 CONDENSER Air cooled Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Thermostatic E xpansion Valve REFRIGERANT CHARGE R 404A 1 Ib 470 g DESIGN PRESSURE High 460 PSIG Low 290 PSIG P C BOARD CIRCUIT PROTECTION High Voltage Cut off Relay COMPRESSOR PROTECTION Auto reset Overload P rotector GEAR MOTOR PROTECTION Manual reset Circuit Breaker REFRIGERANT CIRCUIT PROTECTION Auto reset High Pressure Control S witch LOW WATER PROTECTION Float Switch and Timer ACCESSORIES SUPPLIED Ice Scoop S pare Fuse REQUIRED Legs OPERATING CONDITIONS VOLTAGE RANGE 104 127V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG DRAWING NO DIMENSIONS 339850 We reserve the right to make changes in specifications and design without prior notice 6 General Information 1 Construction F 500BAF F 500BAF C Side Panel Sliding Door Erant Pan
6. LBU R P GY VIOLET IBU 9 CONTROL YELLOW 2 WATER VALVE LBU LIGHTBLUE La BU BLUE 2 5 2 9 BR ki BU 6 DBU k O QO 9 O O 7 FLOAT SWITCH WATER CONTROL RELAY X3 BIN CONTROL SWITCH 0 F 500BAF C 17 Compressor starts about 60 sec after gear motor starts 115 120 60 1 L N START CAP ooto BR W 270 324MED 2 STARTER lt CONTROL 15MFD CIRCUIT PROTECT RELAY X5 GEAR MOTOR PROTECT RELAY X4 PRESSURE SWITCH FUSE 1A CIRCUIT SWITCH THERMAL PROTECTOR GEAR MOTOR CAP K 10MFD i 8 contro f Es 3 L CO 3 0 9 1 5 CONTROL 8 WATER VALVE BIN CONTROL SWITCH WATER CONTROL RELAY X3 F 500BAF C 18 2 j P Kg BU 00807 x 80 FLOAT SWITCH WIRE COLOR CODE BR BROWN W WHITE BK BLACK R RED GY GRAY DBU DARK BLUE V VIOLET Y YELLOW LBU LIGHT BLUE BU BLUE Compressor stops about 90 sec after bin control operates Gear motor stops about 60 sec later and water is drained from the water circuit Water can
7. and B and spout packings A and B in their correct positions 9 Allow the icemaker to sit for about 10 minutes before operation 10 Move the flush switch to the ICE position then turn on the power supply Replace the top panel and the front panel in their correct positions Make ice using the solution until the icemaker stops making ice 11 Remove the front panel 12 Move the flush switch to the FLUSH position to drain the remainder of the solution 13 After the solution is drained move the flush switch to the ICE position 14 Replace the front panel in its correct position 15 Open the water supply line shut off valve and supply water to the reservoir 16 When the gear motor starts remove the front panel and turn off the power supply 17 Drain out all water from the water line See 2 and 3 18 Move the flush switch to the ICE position and run the icemaker 19 Turn off the power supply after 30 minutes 20 Pour warm water into the storage bin to melt all ice then clean the bin liner with the solution 21 Flush out any solution from the storage bin 22 Turn on the power supply and start the automatic icemaking process IMPORTANT 1 After cleaning do not use ice made from the sanitizing solution Be careful not to leave any solution in the storage bin 2 Follow carefully any instructions provided with the bottles of cleaning or sanitizing solution 3 Never run the icemaker when th
8. c Expansion Valve 1 Low side pressure Replace not adjustable too low 2 Low side pressure Seeif Expansion too high Valve Bulb is mounted properly and replace the valve if necessary 29 3 Other PROBLEM POSSIBLE CAUSE 1 Abnormal noise 2 Overflow from Reservoir Water does not stop 3 Gear Motor Fuse blows or Circuit Breaker trips frequently a Refrigerant Lines Rub or touch lines or other surfaces Bearing or Gear worn out damaged high b Control Water Valve 1 Diaphragm does not 1 close Power Supply Too high or too low Voltage Evaporator Assy Bearings or Auger worn out Bad contacts Fan Motor Compressor Gear Motor Ice Making Evaporator Bin Control Bearing worn out 2 Fan blade deformed 3 Fan blade does move freely Bearings worn out or cylinder valve broken 2 pad out of Low side pressure too low 2 Scale on inside wall of Freezing Cylinder 2 Activator does not move freely 1 REMEDY Replace Replace fan blade Replace Replace Reinstall Replace Replace See if Expansion Valve Bulb is mounted properly and replace the valve if necessary Remove Auger Use SCALE AWAY or LIME A WAY solution to clean periodically If the water is found hard by testing install a softener Install a pressure Reducing Valve Clean or replace Check for continuity
9. evacuation and refrigerant charge should be exclusively for POE oils 2 Turn on the vacuum pump Never allow the oil in the vacuum pump to flow backward 3 Allow the vacuum pump to pull down to a 29 9 Hg vacuum Evacuating period depends on pump capacity 4 Close the low side valve and high side valve on the service manifold 31 5 Disconnect the vacuum pump and attach refrigerant service cylinder to the high side line Remember to loosen the connection and purge the air from the hose See the nameplate for the required refrigerant charge Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No 700 88 be used 6 A liquid charge is recommended for charging an R 404A system Invert the service cylinder Open the high side service manifold valve 7 Allow the system to charge with liquid until the pressures balance 8 If necessary add any remaining charge to the system through the low side Use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low side access port with the unit running 9 Close the two refrigerant access valves and disconnect the hoses and service manifold 10 Cap the access valves to prevent a possible leak 2 Brazing WARNING 1 Refrigerant R 404A itself is not flammable at atmospheric pressure and temperatures up to 176 F 2 Refrigerant R 404A itself is not explosive or poisonous However when expose
10. Instructions MUNERE UU 46 Specifications 500 SUPPLY VOLTAGE 115 60 1 COMPRESSOR 120V 7 9 RLA 51 LRA GEAR MOTOR 120V 1 6 FLA 1 6 HP FAN MOTOR 120V 0 85 FLA 1 15 HP OTHER 120 V 0 03 A MAXIMUM FUSE SIZE 20A MAX HACR BREAKER USA ONLY 20A MAX CIRC BREAKER CANADA ONLY MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION i PER 24HR 50 70 9 Ibs day kg day 70 Reference without marks 80 90 100 SHAPE OF ICE Flake ICE QUALITY Approx 70 Ice 90 70 F Conductivity 200 7s APPROXIMATE STORAGE CAPACITY 250 lbs ELECTRIC amp WATER CONSUMPTION 90 70 F 70 50 ELECTRIC W kWH 100 lbs 900 6 0 854 4 3 POTABLE WATER 43 12 57 12 al 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH 38 x 29 x 36 965 x 735 x 915 mm EXTERIOR FINISH PVC Coated Galvanized Steel Galvanized S teel Rear Stainless Steel Top WEIGHT Net 210 Ibs 95 kg Shipping 245 Ibs 111 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Drain Pan 3 4 FPT Bin Drain 3 4 FPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger 1 6 HP Gear Motor ICE MAKING WATER CONTROL Float S witch COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Bin Control P roximity S w COMPRESSOR Hermetic Model RS 43CTE CAA CONDENSER Air cooled Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERA
11. and replace Connect the unit to a power supply of proper voltage Replace Bearing or Auger Check for continuity and replace Clean Axle and its corresponding holes or replace Bin Control V Removal and Replacement of Components IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after the equipment is serviced IMPORTANT The Polyol Ester POE oils used in R 404A units can absorb moisture quickly Therefore it is important to prevent moisture from entering the system when replacing or servicing parts Always install a new filter drier every time the sealed refrigeration system is opened Do not leave the system open for longer than 15 minutes when replacing or servicing parts 1 Service for Refrigerant Lines a Refrigerant Recovery The icemaker unit is provided with two refrigerant access valves one on the low side and one on the high side line Using proper refrigerant practices recover the refrigerant from the access valves and store it in an approved container Do not discharge the refrigerant into the atmosphere b Evacuation and Recharge R 404A 1 Attach charging hoses a service manifold and a vacuum pump to the system Be sure to connect charging hoses to both high side and low side access valves IMPORTANT The vacuum level and vacuum pump may be the same as those for current refrigerants However the rubber hose and gauge manifold to be used for
12. m SWITCH m Bi oc ii WATER CONTROL ON m 7 RELAY OFF CONTROL WATER ON VALVE OFF 6 FLUSH RELAY rush FLUSH SWITCH FLUSH WATER VALVE BIN CONTROL 0 GEAR MOTOR ia 1 lt BEN 2 m Tl 7 12 MOTOR COMPRESSOR 4 PRESSURE SWITCH 21 LOW WATER CONDENSER FAN FAILURE OFF RELAY LH m hl FLOAT Ro O 1 SWITCH EE 4 WATER CONTROL CONTROL WATER en FU RT dd 111007 0 0 S ET on TP VALVE ES S ae qw DL Sec ie gt 0 GEAR MOTOR En aS O ina e LC L 90 sec p 60 sec EN mum tt ty tt 4 PRESSURE a S L L 22 FLUSH SWITCH OFF RELAY 2 WATER LEVEL LL ON UPPER FLOAT SWITCH LOWER 4 WATER CONTROL RELAY a CONTROL WATER VALVE _ Su LT 6 FLUSH RELAY OFF FLUSH FLUSH SWITCH og E 8 FLUSH WATER ON VALVE E BIN CONTROL 150 2 pA sec GEAR MOTOR RELAY 1 GEAR MOTOR 2 FAN MOTOR COMPRESSOR PRESSURE SWITCH 23 5 Performance Data F 500BAF AP
13. ATING 1 2 T3 T4 T5 T6 Fig 3 12 Functions of Terminals 1 Terminals 1 2 Power supply AC 24V 2 Terminals 3 4 Control X1 GM and X2 CM Relays When closed energize X1 GM in 1 sec and X2 CM in 60 sec When opened de energize X1 GM in 150 sec and X2 CM in 90 sec 3 Terminals 5 6 Control X1 GM and X2 CM Relays When opened de energize X1 GM and X2 CM immediately When closed again energize X1 GM in 1 sec and X2 CM in 60 sec 4 Terminals 7 8 9 X1 GM contacts 8 is a movable contact 7 is a make contact and 9 is a break contact 5 Terminals 10 11 Control X2 CM Relays When opened de energize X2 CM immediately When closed energize X2 CM immediately Note 1 X2 Relay is a single pole normally open relay and its terminals are mounted on the relay itself 2 The above operation times are median See Fig 3 for details 13 Technical Information 1 Water Circuit and Refrigerant Circuit F 500BAF F 500BAF C CONTROL WATER SPOUT RESERVOIR EXPANSION VALVE OVERFLOW FLUSH WATER VALVE DRAIN PAN DRAIN Tol 20 ERE m pra PAN CONDENSER FAN MOTOR CONDENSER ACCESS VALVE COMPRESSOR WATER CIRCUIT REFRIGERANT CIRCUIT 14 2 Wiring Diagram F 500BAF F 500BAF C Kt AK AK START BR DBU 270 324MFD STARTER CIRCUIT COMP MOT RU
14. G when brazing the tubings 6 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 7 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge and type 8 Replace the panels in their correct position 9 Plug in the icemaker 34 5 Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigerant circuit exceeds the drier capacity and freezes up at the expansion valve Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repairs or replacement have been made 1 Unplug the icemaker 2 Remove the panels 3 Recover the refrigerant and store it in an approved container if required by an applicable law 4 Remove the expansion valve bulb at the evaporator outlet 5 Remove the expansion valve cover and remove the expansion valve using brazing equipment 6 Braze the new expansion valve with nitrogen gas flowing at the pressure of 3 4 PSIG WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 7 Install the new drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 Evacuate the system Charge it with refrigerant See the nameplate for the required refrigerant charge and type 10 Attach the bulb to the suction line Be sure to s
15. Hoshizaki America Inc Self Contained Flaker Model F 500BAF SERVICE MANUAL of Reliability www hoshizaki com m jd E Number 73074 Issued 3 2 1999 Revised 12 26 2003 IMPORTANT Only qualified service technicians should attempt to service or maintain this icemaker No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should the reader have any questions or concerns which have not been satisfactorily addressed please call or write to the HOSHIZAKI Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn HOSHIZAKI Technical Support Department Phone 1 800 233 1940 Technical Service 770 487 2331 Fax 770 487 3360 Web Site www hoshizakiamerica com Note To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem Please review this manual It should be read carefully before the icemaker is serviced maintenance operations are performed Only qualified service technicians should service and maintain the icemaker This manual should be made available to the technician prior to service or maintenance CONTENTS SN ONS
16. N PROTECTOR CONTROL Wu K SWITCH 0 0 15MFD A BK R PROTECT RELAY X5 GEAR MOTOR CIRCUIT SWITCH PROTECT RELAY Ki GEAR CAP THERMAL PROTECTOR MOTOR 10MFD O PRESSURE SWITCH 7 TIMER CONTROL WATER VALVE FLUSH BIN CONTROL SWITCH K SWITCH 7 WATER CONTROL RELAY X3 0 15 WIRE COLOR CODE BR BROWN BLACK R RED ORANGE GY GRAY DBU DARK BLUE VIOLET Y YELLOW LBU LIGHT BLUE BU BLUE 3 Sequence of Electrical Circuit F 500BAF F 500BAF C a When power switch is moved to ON position and flush switch to ICE position water starts to be supplied to reservoir 11 1 dq 5 L START CAP 11 3 BR T 270 324MFD STARTER 5 comp 3 CONTROL 1 SWITCH 15MFD 2 gk CIRCUIT PROTECT RELAY 5 1 3 4 PROTECT RELA
17. NT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R 404A 1 Ib 470 g DESIGN PRESSURE High 460 PSIG Low 290 PSIG P C BOARD CIRCUIT PROTECTION High Voltage Cut off R elay COMPRESSOR PROTECTION Auto reset Overload Protector GEAR MOTOR PROTECTION Manual reset Circuit Breaker REFRIGERANT CIRCUIT PROTECTION Auto reset High Pressure Control S witch LOW WATER PROTECTION Float S witch and Timer ACCESSORIES SUPPLIED Ice S coop S pare Fuse REQUIRED Legs OPERATING CONDITIONS VOLTAGE RANGE 104 127V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG DRAWING NO DIMENSIONS 339850 We reserve the right to make changes in specifications and design without prior notice B F 500BAF C AC SUPPLY VOLTAGE 115 COMPRESSOR 120 V 7 9 RLA 51 LRA GEAR MOTOR 120 V 1 6 FLA 1 6 HP FAN MOTOR 120 V 0 85 FLA 1 15 HP OTHER 120 V 0 03 A MAXIMUM FUSE SIZE 20A MAX HACR BREAKER USA ONLY 20A MAX CIRC BREAKER CANADA ONLY 20A MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION i PER 24 5 70 90 Ibs day kg day Reference without marks SHAPE OF ICE Cubelet ICE QUALITY Approx 80 Ice 90 70 Conductivity 200 7s APPROXIMATE STORAGE CAPACITY 250 Ibs ELECTRIC amp WATER CONSUMPTION 90 70 70 50 F ELECTRIC W kWH 100 lbs 903 6 5 864 4 8 POTABLE WATER 40 12 52 12 gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH 38 x 29 x 36 965 x 735 x 915 mm
18. PROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR gal day EVAPORATOR OUTLET TEMP F CC HEAD PRESSURE PSIG kg cm G SUCTION PRESSURE kg cm G TOTAL HEAT OF REJECTION Temp F 50 70 478 217 438 80 419 190 383 174 90 366 _ 166 335 152 100 320 145 287 130 70 854 867 80 90 100 70 80 90 199 8 8 am N N N S Note The data without marks should be used for reference We reserve the right to make changes in specifications and design without prior notice 24 500 Ambient Water Temp F ICE PRODUCTION Temp F 50 415 188 24 70 431 196 415 188 398 181 80 381 173 350 159 90 336 152 308 140 Ibs day kg day 100 295 134 263 119 APPROXIMATE ELECTRIC 70 864 CONSUMPTION 80 880 891 90 897 907 watts 100 912 922 APPROXIMATE WATER 70 52 196 48 181 CONSUMPTION PER 24 80 90 gal day 100 EVAPORATOR OUTLET TEMP 70 29 13 9 T1663 9 6 3 80 9 149 12 C10 12 11 90 F 100 HEAD PRESSURE 70 80 2 258 18 1 90 kg cm G 100 SUCTION PRESSURE 70 80 90 PSIG kg cm G 100 TOTAL HEAT OF REJECTION 70 F 3 1 o m 59 N
19. Y o O X4 5 6 Ki 7 8 5 CIRCUIT THERMAL GEAR CAP SWITCH PROTECTOR MOTOR 10MFD Kor 1 V ca g CAP CONDENSERFANMOTOR xg 2 5 NR PRESSURE DBU ON SWITCH BK ia WIRE COLOR CODE W BR BROWN w WHITE CONTROL 4 0 BR BK BLACK TIMER R RED 3 R ORANGE 9 9 6 4 D D 5 59 AE FLUSH WATER 0 DBU DARKBLUE N x E BR V VIOLET ty CONTROL Y YELLOW K VALVE LBU LIGHTBLUE BU BLUE 1 2 1 2 BR 3 4 80 DBU LO Oooo To 9l K BK FLOAT SWITCH WATER CONTROL RELAY X3 BIN CONTROL SWITCH 0 F 500BAF C 16 6 When reservoir has been filled up gear motor starts immediately 115 120 60 1 L N ai dbi in dunes START CAP 1 270 324MFD A T STARTER 5 5 3 O 3 comp PROTECTOR CONTROL SWITCH CIRCUIT PROTECT RELAY X5 2 2 0 PROTECT RELAY X4 CIRCUIT SWITCH THERMAL PROTECT PRESSURE SWITCH WIRE COLOR CODE BR BROWN w WHITE TRANS 8 7 CONTROL 4 0 BR BK BLACK q 9000 Es TIMER R RED BK BK 9e R FUSE 1 CO 2 0 6 40 9 FLUSH WATER DBU DARKBLUE
20. ant 4 5 Refrigerant line or 5 6 Bad contacts 6 7 Loose connections 7 1 REMEDY Replace Check for continuity and replace Replace Clean Get cooler See 3 1 a Fan Motor Recharge Clean and replace drier Check for continuity and replace Tighten Check for continuity and replace Replace Timer Check for continuity and replace Replace Tighten Replace 27 PROBLEM POSSIBLE CAUSE REMEDY Compressor Loose connections Tighten 2 Motor winding Replace opened or grounded 3 Protector Find out the cause of Pe overheat or overcurrent Power Supply too 1 Install larger sized conductor 5 Gear Motor and a Refrigerant Line 1 Gus leaks Check for leaks with a Compressor start leak detector Reweld but no ice is leak replace drier and produced charge with refrigerant The amount of refrigerant is marked on Nameplate or Label 2 Refrigerant line Replace the clogged clogged component 28 2 Low Production PROBLEM POSSIBLE CAUSE REMEDY 1 Low ice production Refrigerant Line 1 Gas leaks See 1 5 a Refrigerant Line 2 Refrigerant line Replace the clogged clogged component 3 Overcharged Recharge b High side Pressure 1 Dirty Air Filter or Clean Too High Condenser 2 Ambient temperature 2 cooler too warm 3 Fan rotating too See 3 1 a Fan slow Motor
21. be also drained by moving flush switch to FLUSH position 115 120 60 1 1 eb 3j E 2 5 STARTER O4 3 9 O CONTROL ula 15MFD KA CIRCUIT PROTECT RELAY X5 1 GEARMOTOR 3 PROTECT RELAY 4 CIRCUIT THERMAL GE SWITCH PROTECTOR MOTOR OGSA GY BK 0 61 CONDENSER FAN MOTOR b mi SWITCH WIRE COLOR CODE BR BROWN W WHITE 0 C contra 1 BK BLACK TIMER R RED 94 e R 0 FUSE 1 7 2 3 6 6 49 GY GRAY ND 1 FLUSH WATER 0 DBU DARKBLUE AMEZ Y di See um zi V VIOLET O 00 O e CONTROL Y YELLOW K WATER VALVE LBU LIGHTBLUE BU BU p FLUSH RELAY X6 em FLUSH K SWITCH FLOAT SWITCH WATER CONTROL RELAY P LBU X3 BIN CONTROL SWITCH 0 500 19 e When 208 230V are supplied to the power supply due to miswiring circuit protect relay operates and the icemaker does not run 115 120 60 1 DBU _L start 1 270 324MFD 2 5 STARTER 0 K COMP MOT CONTROL SWITCH 15MFD
22. d to high temperatures open flames R 404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous 3 Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere 4 Do not use silver alloy or copper alloy containing arsenic 5 Do not use R 404A as a mixture with pressurized air for leak testing Refrigerant leaks can be detected by charging the unit with a little refrigerant raising the pressure with nitrogen and using an electronic leak detector Note All brazing connections are clear paint coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove coating 32 3 Removal and Replacement of Compressor IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Unplug the icemaker 2 Remove the panels 2 Remove the terminal cover on the compressor and disconnect the compressor wiring 3 Recover the refrigerant and store it in an approved container if required by an applicable law 4 Remove the discharge suction and access pipes from the compressor using brazing equipment WARNING When repairing a refrigerant system be careful not to let the burner flame contact any electrical wires or insulation 5 Remove the bolts and rubbe
23. e and high quality control system 3 All models are pre tested and factory adjusted b Timer Board CAUTION Fragile handle very carefully A timer board contains CMOS Complementary Metal Oxide Semiconductor integrated circuits which are susceptible to failure due to static discharge It is especially important to use an anti static wrist strap when handling or replacing the board Do not touch the electronic devices on the board or the back of the board to prevent damage to the board Do not change wiring and connections Especially never misconnect terminals Do not fix the electronic devices or parts on the board in the field Always replace the whole board assembly when it goes bad The icemaker is controlled by the timer board for the following purposes 1 To prevent the gear motor and the compressor from starting or stopping simultaneously 2 To reduce remaining ice in the refrigeration casing 3 To protect the unit in case of low water and low water pressure 4 To protect the unit in case the bin control causes chattering 10 Compressor Relay 2 G4FN 1112TP DC24V Gear Motor Relay 2315104 CONTROL CTL De _ Dur 1 1 f ri T 1 _ GEAR MOTOR OFF 11 COMPRESSOR OFF PART CODE 437305 01 MODEL R
24. e reservoir is empty 45 3 Maintenance Instructions IMPORTANT 1 This icemaker must be maintained individually referring to the instruction manual and labels provided with the icemaker 2 To have the optimum performance of this icemaker the following consumable parts need periodic inspection maintenance and replacement Extruding Head Housing Gear Motor Auger Mechanical Seal These parts should be inspected at least once a year or every 10 000 hours of operation Their service life however depends on water quality and environment More frequent inspection and maintenance are recommended Consult with your local distributor about inspection and maintenance service To obtain the name and phone number of your local distributor call Hoshizaki Technical Support at 1 800 233 1940 in the USA 1 Stainless Steel Exterior To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up 2 Storage Bin and Scoop Wash your hands before removing ice Use the plastic scoop provided bin accessory The storage bin is for ice use only Do not store anything else in the bin Keep the scoop clean Clean using a neutral cleaner and rinse thoroughly Clean the bin liner using a neutral cleaner Rinse thoroughly after cleaning 46 3 Air Filter A plastic mesh air filter removes dirt or dust from the air and keeps the cond
25. ecure the bulb using a band and to insulate it 11 Place the expansion valve cover in position 12 Replace the panels in their correct position 13 Plug in the icemaker 35 6 Removal and Replacement of Evaporator Assembly 1 Drain the water from the evaporator by switching the flush switch to FLUSH on the control box 2 Unplug the icemaker 3 Remove the panels 4 Remove the three thumbscrews and take off the spout from the evaporator Cutter 5 Loosen the cutter by a wrench and remove it 6 Remove the cylinder gasket at the top of the evaporator Extruding Head 7 Grasp the top of the auger and move the 02 Round Stock or Pin Gauge auger towards you and then try to insert a 02 round stock or pin gauge in between the back side of the auger shaft and the bearing surface Check several locations around the auger shaft If the gauge goes between the shaft and the bearing at any X Head point both the top bearing in the extruding i head and the lower bearing in the housing should be replaced Instructions for removing the housing are located later in this procedure Note Replacing the bearing requires a bearing press adaptor If one is not available replace the whole extruding head and housing 8 Remove the three socket head cap screws and lift off the extruding head Auger 9 Lift out the auger If the area in contact with the bearing is worn or the blade is scratched replace the a
26. el Water Supply Inlet Control Water Valve Spout Gear Motor Evaporator Access Valve P Condenser Compressor Control Box Condenser Fan 2 Making Unit CUTTER EXTRUDING HEAD SOCKET HEAD CAP SCREW M8 x 14 AUGER p CYLINDER INSULATION MECHANICAL SEAL O RING G40 SOCKET HEAD CAP SCREW BEARING LOWER COUPLING SPLINE _HEXAGON HEAD BOLT 4 6 20 3 Control Box Layout F 500BAF F 500BAF C PRESSURE SWITCH dum CONNECTOR CONTROL la TIMER TRANSFORMER FLUSH VALVE CONTROL RELAY STARTER FLUSH SWITCH ICE 1 1 on G9 E POWER SWITCH CAPACITOR G X 2 OE FUSE _ CIRCUIT PROTECT RELAY CIRCUIT BREAKER START CAPACITOR GEAR MOTOR PROTECT RELAY CAPACITOR FOR CAPACITOR FOR GEAR MOTOR FAN MOTOR WATER CONTROL RELAY Note The above component names are identical with the wiring label but not with the parts list 4 Timer Board a Solid State Control 1 A HOSHIZAKI exclusive solid state control is employed in the self contained flaker icemakers 2 A printed circuit board hereafter called timer board includes a stabl
27. enser from getting clogged As the filter gets clogged the icemaker s performance will be reduced Check the filter at least twice a month When clogged use warm water and a neutral cleaner to wash the filter 4 Condenser Check the condenser once a year and clean if required by using a brush or vacuum cleaner More frequent cleaning may be required depending on the location of the icemaker 47
28. he water supply line shut off valve 3 Remove all ice from the storage bin 4 Move the flush switch to the FLUSH position 5 Turn on the power supply and drain out all water from the water line 6 Turn off the power supply Note This unit is designed to start operating when the reservoir is filled with water 7 In the storage bin remove the thumbscrews attaching spout B then remove spout B and spout packing B Thumbscrews 42 8 Remove the thumbscrews attaching spout A to the evaporator assembly lift off spout A and spout packing A 9 Pour the cleaning solution over the extruding head until the evaporator assembly and the reservoir are filled and the solution starts to overflow into the drain pan Note If there is excess scale on the extruding head fill the evaporator assembly and reservoir as described above then use a clamp on the reservoir hose between the reservoir and evaporator assembly to block flow Pour additional cleaning fluid over the extruding head until the evaporator assembly is completely full 10 Using the thumbscrews replace spouts A and B and spout packings A and B in their correct positions 11 Allow the icemaker to sit for about 10 minutes before operation If you placed a clamp on the reservoir hose in step 9 remove it before operation 12 Move the flush switch to the ICE position then turn on the power supply Replace the top panel and the front pa
29. nd the wire connectors 7 Replace the panels in their correct position 8 Plug in the icemaker 8 Removal and Replacement of Control Water Valve 1 Unplug the icemaker 2 Remove the panels 3 Close the water supply line shut off valve 4 Disconnect the terminal from the control water valve 5 Loosen the fitting nut on the control water valve inlets and remove the control water valve Do not lose the packings inside the fitting nut 6 Remove the water supply hose from the control water valve 7 Install the new control water valve 8 Assemble the removed parts in the reverse order of the above procedure 9 Open the water supply line shut off valve 10 Check for water leaks 11 Replace the panels in their correct position 12 Plug in the icemaker 40 Cleaning and Maintenance IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment 1 Preparing Icemaker for Long Storage WARNING When shutting off the icemaker for an extended time drain out all water from the water line and remove the ice from the storage bin The storage bin should be cleaned and dried Drain the icemaker to prevent damage to the water supply line at sub freezing temperatures using air or carbon dioxide Shut off the icemaker until the proper ambient temperature is resumed 1 Run the icemaker with the water supply line shut off valve cl
30. nel in their correct positions Make ice using the solution until the icemaker stops making ice 13 Remove the front panel 14 Move the flush switch to the FLUSH position to drain the remainder of the solution 15 After the solution is drained move the flush switch to the ICE position 16 Replace the front panel in its correct position 17 Open the water supply line shut off valve and supply water to the reservoir 18 When the gear motor starts remove the top panel and front panel Turn off the power supply 19 Drain out all water from the water line See 4 through 6 c Sanitizing Solution Dilute 2 5 fl oz 74 ml or 5 tbs of IMS II Sanitizer or a 5 25 sodium hypochlorite solution chlorine bleach with 5 gallons 191 of warm water IMPORTANT For safety and maximum effectiveness use the solution immediately after dilution 43 Sanitizing Procedure Initial 1 Close the water supply line shut off valve 2 In the storage bin remove the thumbscrews attaching spout B then remove spout B and spout packing B 3 Remove the thumbscrews attaching spout A to the evaporator assembly and lift off spout A and spout packing A and the cylinder packing 4 Pour the sanitizing solution over the extruding head until the evaporator assembly and the reservoir are filled and the solution starts to overflow into the drain pan 5 Remove the thumbscrews attaching the bin control Bracket a
31. osed 2 Open the drain valve and blow out the water inlet line by using air pressure 3 Turn off the power supply 4 Remove the front panel 5 Move the flush switch on the control box to the FLUSH position 6 Turn on the power supply and then drain out all water from the water line 7 Turn off the power supply 8 Turn off the power switch on the control box Shut olf Valve 9 Replace the front panel in its correct position 10 Close the drain valve Drain Valve 11 Remove all ice from the storage bin and clean the bin Air or CO2 41 2 Cleaning and Sanitizing Instructions WARNING 1 HOSHIZAKI recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water conditions 2 To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners 3 Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin a Cleaning Solution Dilute 4 8 fl oz 142 ml of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 0 8 gallons 3 of warm water This is minimum amount Make more solution if necessary IMPORTANT For safety and maximum effectiveness use the solution immediately after dilution b Cleaning Procedure 1 Remove the front panel and the top panel then turn off the power supply 2 Close t
32. r grommets 6 Slide and remove the compressor Unpack the new compressor package Install the new compressor 7 Attach the rubber grommets of the prior compressor 8 Sandpaper the discharge suction and access pipes 9 Place the compressor in position and secure it using the bolts 10 Remove plugs from the discharge suction and access pipes 11 Braze the access suction and discharge lines Do not change this order while purging with nitrogen gas flowing at the pressure of 3 4 PSIG 12 Install the new drier 33 13 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 14 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge and type 15 Connect the terminals to the compressor and replace the terminal cover in its correct position 16 Replace the panels in their correct position 17 Plug in the icemaker 4 Removal and Replacement of Drier IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Unplug the icemaker 2 Remove the panels 3 Recover the refrigerant and store it in an approved container if required by an applicable law 4 Remove the drier using brazing equipment 5 Install the new drier with the arrow on the drier in the direction of the refrigerant flow Use nitrogen gas at the pressure of 3 4 PSI
33. s a bearing press adaptor If one is not available replace the whole extruding head and housing 37 Gear Motor 20 Remove the coupling spline on the gear motor shaft 21 Remove the three bolts securing the gear motor 22 Assemble the removed parts in the reverse order of the above procedure WARNING Be careful not to scratch the surface of the O ring or it may cause water leaks Handle the mechanical seal with care not to scratch nor to contaminate its contact surface 23 When replacing the evaporator a Braze the new evaporator with nitrogen gas flowing at the pressure of 3 4 PSIG b Replace the drier c Check for leaks using nitrogen gas 140 PSIG and soap bubbles d Evacuate the system Charge it with refrigerant See the nameplate for required refrigerant charge and type 24 Replace the panels in their correct position 25 Plug in the icemaker 38 EN Bp Cutter Extruding Head Auger Socket Head Cap Screw Dw Spring Retainer Evaporator Mechanical Seal Hexagon Socket Cap Bolt with O ring Washer 70 gt Bearing Lower Coupling Barrier Gear Motor 39 7 Removal and Replacement of Fan Motor 1 Unplug the icemaker 2 Remove the panels 3 Remove the wire connectors from the fan motor leads 4 Remove the fan motor bracket and fan motor 5 Install the new fan motor 6 Replace the fan motor bracket a
34. ssembly to the inside of the bin top panel Thumbscrews 6 Remove the snap pin shaft and actuator Snap Pin Shaft 7 Remove the sliding door Actuator 8 Soak the removed parts in 25 gallons 1 1 of sanitizing solution for 10 minutes then wipe them down Fig 5 9 Rinse the parts thoroughly IMPORTANT If the solution is left on these parts they will rust 10 Replace all parts in their correct positions 11 Move the flush switch to the ICE position then turn on the power supply Replace the top panel and the front panel in their correct positions Make ice using the solution until the icemaker stops making ice e Sanitizing Procedure Final 1 Remove the front panel and the top panel then turn off the power supply 2 Move the flush switch to the FLUSH position 3 Turn on the power supply and drain out all water from the water line 4 Turn off the power supply Note This unit is designed to start operating when the reservoir is filled with water 5 In the storage bin remove the thumbscrews attaching spout B then remove spout B and spout packing B 44 6 Remove the thumbscrews attaching spout A to the evaporator assembly lift off spout A and spout packing A 7 Pour the sanitizing solution over the extruding head until the evaporator assembly and the reservoir are filled and the solution starts to overflow into the drain pan 8 Using the thumbscrews replace spouts A
35. ter does not a Water Control Relay Contact fused Replace stop and the icemaker will not 2 Coil winding opened 2 Replace m start b Float Switch 1 Bad contacts 1 Check for continuity and replace 2 Float does not move 2 Clean or replace freely Flush Water Valve Valve seat clogged Clean or replace and water leaking Disconnected Connect Water has been a Water Control Relay Bad contacts Check for continuity supplied but the and replace icemaker will not b Bin Control popa 3 contacts Check for continuity start and replace 2 iL NEN does not Clean axle and its move freely corresponding holes or replace Bin Control c Gear Motor 1 Tripped Find out the cause Protector get rid of it and press Circuit Breaker Reset Button on Circuit Breaker 26 PROBLEM POSSIBLE CAUSE d Gear Motor Protect 1 Relay e Control Timer Printed Circuit Board Pressure Switch 4 Gear Motor starts a but Compressor will not start or operates intermittently 1 Dirty Air Filter or Condenser too warm overcharged components plugged b X2 Relay on Control 1 Bad contacts Timer 2 Coil winding opened 2 Starter 1 Bad contacts 1 2 Coil winding opened 2 3 Loose Connections 3 Defective 1 d Start Capacitor or 1 Run Capacitor Coil winding opened 1 2 Bad contacts 2 1 2 Ambient temperature 2 3 Fan not rotating 3 4 Refriger
36. uger 36 Evaporator Note Skip the following steps 10 through 12 when the evaporator does not need replacement 10 Recover the refrigerant and store it in an approved container if required by an applicable law IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 11 Remove the bulb of the expansion valve 12 Disconnect the brazing connections of the expansion valve and the copper tube low side from the evaporator using brazing equipment 13 Remove the two truss head machine screws and the bracket securing the evaporator 14 Disconnect the three hoses from the evaporator 15 Remove the four socket head cap screws securing the evaporator with the bearing lower 16 Lift off the evaporator Housing Lower Bearing and Mechanical Seal 17 The mechanical seal consists of two parts One moves along with the auger and the other is fixed on the housing If the contact surfaces of these two parts are worn or scratched the mechanical seal may cause water leaks and should be replaced 18 Remove the O ring from the housing 19 Remove the four bolts and the housing from the gear motor If inspection of the bearing inside the extruding head earlier in this procedure indicated that it is out of tolerance replace both it and the bearing inside the housing Note Replacing the bearing require
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