Service Manual
Contents
1. SETS 33 Me 34 V Removal and Replacement of Components 35 1 Service for R frigerant ud edid uiuit 35 a Refrigerant Recovery 35 b Evacuation and Recharge 35 2 iris M 36 Removal and Replacement of 37 4 Removal and Replacement of Drier 38 5 Removal and Replacement of Expansion 39 6 Removal and Replacement of Evaporator Assembly 40 7 Removal and Replacement of Fan Fato 42 8 Removal and Replacement of Control Water Valve 42 9 Removal and Replacement of Flush Water Valve 43 VI Cleaning and 44 1 Preparing the icemaker Tor Long Storage 44 2 Cleaning and Sanitizing 45 Cleaning 45 b en a ER RI 462. teeta 47 d Sanitizing Precedure Initislosueu s ui 47 Sanitizing Procedure Final 48 3 Maintensmes 50 I Specifications 1 F 450MAH AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR OTHER MAXIMUM FUSE SIZE MAX HACR BREAKER USA ONLY MAX CIRC BREAKER CANADA ONLY MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC KWH 100 Ibs POTABLE WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN ICE MAKING SYSTEM HARVESTING SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION GEAR MOTOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES REQUIRED OPERATING CONDITIONS 115 60 1 120 8 5 RLA 51 LRA 120 V 1 6 FLA 1 6 HP 115 V 0 85FLA 50W 120 V 0 03A 20A 20A 20A 20A CF 50 70 90 Flake Approx 7096 Ice 90 70 Conductivity 200 us cm N A 90 70 70 50 F 915 6 2 858 4 3 43 12 57
3. 31 Compressor start but no ice is produced b Refrigerant Line 1 1 PROBLEM POSSIBLE CAUSE REMEDY 7 Gear Motor and a Check for leaks with a leak detector Reweld leak replace drier and charge with refrigerant The amount of refrigerant is marked on Nameplate or Label 2 Refrigerant line 2 Replace the clogged clogged component Shut off Valves 1 Closed 1 Open Condensing Unit 32 2 Low Ice Production PROBLEM POSSIBLE CAUSE REMEDY 1 Low ice production a Refrigerant Line Gas leaks See 1 5 a Refrigerant Line 2 Refrigerant line 2 Replace the clogged clogged component 3 Overcharged 3 Recharge Too High Condenser 2 Ambient temperature 2 Get cooler too warm 3 Fan rotating too 3 See 3 slow Motor 4 unit out 4 Check condensing of order unit not adjustable too low 2 Low side pressure 2 See if Expansion too high Valve Bulb is mounted properly and replace the valve if necessary 33 3 Other PROBLEM POSSIBLE CAUSE REMEDY 1 Abnormal noise a Fan Motor 1 Bearing worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade 3 Fan blade doesnot 3 Replace move freely Compressor 1 Bearings worn out 1 Replace or cylinder valve broken 2 Mounting 2 Reinstall ae d Refrigerant Lines Rub or touch lines or 1 Replace other surfaces Gear Motor Ice Bearing or Gear Replace Mak
4. RUN 25990 FLUSH SWITCH 0 FLUSH TIMER 8 1 1 ROS Ll PROTECTOR FUSE 2 3 R E GEAR CAP ROTOR 12080 2 UI W f When flush switch is moved to FLUSH position flush water valve opens and flushes reservoir and evaporator BK BLACK 0 ORANGE BR BROWN P PINK DARK R RED 2 V VIOLET 115 120 60 1 LBU LIGIT BLUE W WHITE Y YELLOW 4 TART STARTER TELS RUN 231 t THERMAL PROTECTOR R HOTOR 12070 P AM AIR COOLED MODEL ONLY 20 9 When flush timer operates for 21 min every 12 hours flush water valve opens and flushes reservoir and evaporator BK BLACK 0 ORANGE BR BROWN WU RED 115 120 60 1 LOWE T YELLOW N power 8 d WITCH 5 Sgt 115888 RIN CAP 29050 PROTECT t x FLUSH SWITCH FLUSH THE THER BR CONTROL TIMER THERMAL PROTECTOR R 154 0 gt GEAR CAP MOTOR re FAN HOTOR BR L P AIR COOLED KODEL ONLY 21 h When 208 230V are supplied to circuit protect relay it protects the circuit from being miswired If the power supply is properly connected the
5. 10 365 16 350 32 lbs day kg day APPROXIMATE ELECTRIC 891 CONSUMPTION 913 90 96 watts 861 APPROXIMATE WATER CONSUMPTION PER 24 HR 494 185 Lm 3 um 5 3 9 gal day 36 EVAPORATOROUTLETTEMP 70 3 46 16 7 23 L 1 9 11 431 91 43 20 HEAD PRESSURE 80 257 181 257 181 257 90 289 203 289 203 289 203 PSIG SUCTION PRESSURE 80 31 22 2 22 31 22 90 34 22 24 34 24 PSIG kg cm G 400 3 25 3 26 37 26 TOTAL HEAT OF REJECTION 5150 BTU h AT 90 F WT 70 F We reserve the right to make changes in specifications and design without prior notice 29 IV Service Diagnosis 1 No Ice Production PROBLEM POSSIBLE CAUSE a Power Supply 1 The icemaker will not start Water does not stop and the icemaker will not start Water has been supplied but the icemaker will not start b Power Switch Control Box OFF position 2 Loose connection 2 3 Bad contacts 3 4 Blown fuse 4 Off position 2 Bad contacts d Circuit Protect Relay 1 e Flush Timer f Flush Switch g Transformer h Control Water Valve i Shut off Valve ug and Receptacle 1 PI Control Box a Water Control Relay b Float Switch Flushing out
6. 12 21 7 8 x 27 3 8 x 21 61 64 556 x 696 x 557 7mm Stainless Steel Galvanized Steel Rear Net 150 Ibs 68 kg Shipping 175 Ibs 80 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 Auger type Direct Driven Auger 1 6 HP Gear Motor Float Switch N A Mechanical Bin Control Proximity Sw Hermetic Model RS43C1E CAA 219 Air cooled Fin and tube type Copper Tube on Cylinder Thermostatic Expansion Valve R 404A 1 Ib 455 g High 427 PSIG Low 230 PSIG High Voltage Cut off Relay Internal Protector Manual reset Circuit Breaker or Fuse Auto reset High Pressure Control Switch Float Switch and Timer Ice Storage Bin VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG We reserve the right to make changes in specifications and design without prior notice 4 2 F 450MAH C AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR OTHER MAXIMUM FUSE SIZE MAX HACR BREAKER USA ONLY MAX CIRC BREAKER CANADA ONLY MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs POTABLE WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN ICE MAKING SYSTEM HARVESTING SYSTEM ICE
7. 5A intermittently d Compressor e Power Supply Gear Motor and a Pressure Switch Compressor start but operate intermittently Gear Motor Relay Gear Motor Protect Gear Motor Fuse b Thermal Protector 2 Bad contacts Gear Motor a X2 Relay on Control 1 Bad contacts Timer not start or operates ud 2 Coil winding opened b Starter 1 Bad contacts 2 Coil winding opened 3 Loose connections Start Capacitor or 1 Defective Run Capacitor Coil winding opened 1 Replace 1 2 Bad contacts 2 Check for continuity and replace 1 1 Coil winding opened 11 Replace 2 contacts 2 Check for continuity and replace 1 Blown Fuse 1 See 3 3 Find out the cause and replace the Fuse and replace and replace and replace 1 Replace 1 2 Replace 3 Find out the cause of overheat or overcurrent 1 Install a larger sized conductor 1 Dirty Air Filter or 1 Clean Condenser 2 Ambient temperature 2 Get cooler too warm 3 Fan not rotating 3 See 1 a Fan Motor 4 Recharge overcharged 5 Refrigerant line or 5 Clean and replace components plugged drier Loose connections 2 Motor winding opened or grounded 3 Motor Protector tripped 1 Circuit Ampacity too low 6 Check for continuity and replace 7 Tighten o B 00 20 o gt 5 2 5 Q o 7 Loose connections
8. contact of circuit protect relay does not move even when the coil is energized OK BLACK 0 BR BROWN Peas apr R 115 120 60 1 LBU LIGHT BLUE W Voss 20 15 66 86 BR FLOAT SWITCH 080 Ko PRESSURE SWITCH gt CONTROL TIMER a 9119 4 Q b V pen Bii THERMAL CONTROL PROTECTOR sica ep 475 I GEAR CAP MOTOR 120 COOLED MODEL ONLY 22 PROTECTOR 115 120 60 1 i When pressure switch opens power supply to the control board is cut off causing the compressor and gear motor to turn off immediately BK BLACK 0 ORANGE BR BROW PINK DBU DARK BLUE R RED GY GRAY LBU LIGHT BLUE Y YELLOW BR 18 BR ONTROL TIMER B 0 FLOAT SWITCH PRESSURE SW LTCH GEAR MOTOR PROTECT RELAY 10 1 ULT LJ 21 93 07 e M PESE THERMAL PROTECTOR GEAR MOTOR 128 1 al AIR COOLED HODEL ONLY 23 j When input voltage is too low less than 70 gear motor fuse 1 5 is blown Causing compressor and gear motor to turn off immediately BLACK 0 O
9. 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 rubber 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 37 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 59 2 2 J 5 IMPORTAN
10. worn or the blade is scratched replace the auger 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 40 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 Bearing Lower and Mechanical Seal 17 The mechanical seal consists of two parts One moves along with the auger and the other is fixed on the bearing lower 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 on the bearing lower 19 Remove the four bolts and the bearing lower from the gear motor Replace the bearing inside the bearing lower if it exceeds the wear tolerance of 0 02 or is scratched Note Replacing the bearing requires a bearing pre
11. 2 Badcontacts FLUSH position 2 Bad contacts Coil winding opened Coil winding opened Closed 2 Water failure Disconnected Contacts fused 2 Coil winding opened 2 1 Bad contacts 1 2 Float does not move 2 freely Flush Water Valve Valve seat clogged and water leaking Water Control Relay Bad contacts b Bin Control 30 Disconnected ee contacts 2 does move freely 2 Terminal out of Plug 2 or Receptacle REMEDY Move to ON position Tighten Check for continuity and replace Replace Move to ON position Check for continuity and replace Check for short circuit and replace Check power supply voltage and wire properly Wait for 21 minutes Check for continuity and replace Move to ICE position Check for continuity and replace Replace Replace Open Wait till water is supplied Connect Insert Terminal back in position Replace Replace Check for continuity and replace Clean or replace Clean or replace Connect Check for continuity and replace Check for continuity and replace Clean Axle and its corresponding holes or replace Bin Control PROBLEM POSSIBLE CAUSE REMEDY Control Timer Printed Circuit Board 9 4 Water has been a supplied Fan Motor starts but Compressor and Gear Motor will not start Gear Motor starts but Compressor will Bussman GMD 1
12. ATER SUPPLY PRESSURE 10 113 PSIG We reserve the right to make changes in specifications and design without prior notice 5 1 General Information 1 Construction Water Supply Control Water Valve Inlet Bin Control Junction Box Ice Chute Condenser Evaporator Flush Water 8 85 ined Compressor Control Box Drier Gear Motor 2 Control Box Layout J WATER CONTROL TRANSFORMER RELAY FLUSH ITCH PRESSURE SWITCH POWER GEAR MOTOR ITCH PROTECT RELAY FUSE CONTROL BOARD EI ob MOTOR n n All n nn nin __ STARTER 7 5 START RUN CAPACITOR CAPACITOR Note The above component names are identical with the wiring label but not with the parts list 3 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 stable 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 Semicon ductor integrated circuits which are susceptible to failure due to static discharge It is especially impor
13. F RELAY S ee es 2 WATER LEVEL 3 FLOAT SWITCH LOWER 4 WATER CONTROL RELAY 1111 LL ILU a 1 5 CONTROL WATER VALVE 1 2 6 FLUSH TIMER 2 3 FLUSH 7 FLUSH SWITCH ICE 8 FLUSH WATER VALVE 9 BIN CONTROL 10 GEAR MOTOR RELAY _ 2E S m 27 12 FAN MOTOR 13 COMPRESSOR 14 PRESSURE SWITCH ON OFF ON OFF ON OFF on fe 1 ON OFF ON OFF ON OFF 5 Performance Data a F 450MAH APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR gal day l day HEAD PRESSURE PSIG 2 SUCTION PRESSURE PSIG kg cm G TOTAL HEAT OF REJECTION Water Temp F ate a 164 142 907 98 70 25 158 25 158 225 80 256 180 256 180 256 90 286 201 26 201 286 324 228 32 228 324 70 28 25 80 3 1 21 31 21 31 338 10 37 26 37 26 37 4724 BTU h AT 90 F WT 70 70 F We reserve the right to make changes in specifications and design without prior notice 28 450 Water Temp F ICE PRODUCTION a ee te p PER 24 HR 180 mo 380
14. Hoshizaki America Inc Modular Flaker Models F 450MAH C A Superior 5 E RVI M A UA L of Reliability www hoshizaki com m Issued 8 25 2009 IMPORTANT Only qualified service technicians should install service and maintain the icemaker No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual Failure to service and maintain the equipment in accordance with this manual may adversely affect safety performance component life and warranty coverage 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 write or send an e mail message 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 Support 770 487 2331 Fax 1 800 843 1056 770 487 3360 E mail techsupport hoshizaki com Web Site www hoshizaki 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 servi
15. MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION GEAR MOTOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES REQUIRED OPERATING CONDITIONS 115 60 1 120 120 115 V 120 20A 20A 20A 20A Ambient Temp F 50 70 90 70 8 5 RLA 51 LRA 1 6 FLA 1 6 HP 0 85FLA 50W 0 03A 80 368 167 350 159 333 151 90 317 144 310 141 287 130 100 273 124 260 118 244 111 Cubelet Approx 80 Ice 90 70 F Conductivity 200 us cm N A 90 70 F 70 50 F 956 7 4 880 5 0 37 12 51 12 21 7 8 x 27 3 8 x 21 61 64 556 x 696 x 557 7mm Stainless Steel Galvanized Steel Rear Net 150 Ibs 68 kg Shipping 175 Ibs 80 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT Auger type Direct Driven Auger 1 6 HP Gear Motor Float Switch N A Infrared Sensor Hermetic Model RS43C1E CAA 219 Air cooled Fin and tube type Copper Tube on Cylinder Thermostatic Expansion Valve R 404A 1 Ib 455 g High 427 PSIG Low 230 PSIG High Voltage Cut off Relay Internal Protector Manual reset Circuit Breaker or Fuse Auto reset High Pressure Control Switch Float Switch and Timer Ice Storage Bin VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F W
16. PORTANT For safety and maximum effectiveness use the solution immediately after dilution d Sanitizing Procedure Initial The sanitizing process will sanitize the icemaker 1 Close the water supply line shut off valve 2 Remove the strap connecting the spout to the chute assembly 3 Remove the thumbscrews securing the spout and lift it off Remove the rubber O ring and nylon O ring at the top of the cylinder and also remove the packing between the spout and the chute 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 two thumbscrews securing the proximity switch to the chute assembly 6 Remove the chute assembly from the icemaker 7 Remove the packing at the bottom of the ice chute 8 Remove the three ties and the chute insulation 9 Remove the six wing nuts and two baffles 10 Remove the two thumbscrews the plate and the packing from the top of the ice chute then remove the bin control assembly by sliding it slightly toward the chute opening and lifting it off 11 Disassemble the bin control assembly by removing the two snap pins shaft and actuator 12 Soak the removed parts in 25 gallons 11 of sanitizing solution for 10 minutes then wipe them down 13 Rinse the parts thoroughly IMPORTANT If the solution is left on these parts they will rust 47 14 Replac
17. R BD R BR ER 0 MOTOR 12 ey YY CONDENSER FAN MOTOR 180 2 AIR COOLED HODEL ONLY 13 b F 450MAH C KAKO 0 RNE 11512076071 EM DBU DARK BLUE L i V VIOLET JP La LIT Y OT SWITH 3 START UP STARTER 20 38 k R FUSE GY 1 CONTROL 1 RELAY 49 9 1 22222220 FLOAT GEAR T RELAY CIRCUIT PROTECT RELAY B 19g EI 27 mV i CONTROL TIHER 0 BR 51119 a 18 Ot 7 THERMAL um PROTECTOR D p T 8 3 R ER LBU MOTOR 1240 COMJENSER FAN MOTOR AR UO Wey y 14 3 Sequence of Electrical Circuit a When power switch is moved to ON position and flush switch to ICE position water starts to be supplied to reservoir ORANGE BR BROW PING e CE LU LIGHT BLUE X WHITE RUN 25 9 OBO ucce FLOAT SWITCH ABE gy R MTR b 9 1 al bean GEAR EM MOTOR TT M PPP rio 2 P m AIR COOLED MODEL ONLY 15 b When reservoir has
18. RANGE BR BROW P PINK DBU DARK BLUE R RED GY GRAY 115 120 50 1 LBU LIGHT BLUE W WHITE Y YELLOW N per START CAP STARTER _ 124 F RN CAP 296 MOT PROTECTOR 1 NES b At TIMER B 9 2 LJ Yo P GEAR MOTOR 128 a AIR COOLED HODEL ONLY 24 4 Timing Chart 1 CIRCUIT PROTECT RELAY 2 WATER LEVEL ON UPPER OFF 3 FLOAT WITCH SWITC LOWER OFF 4 WATER CONTROL RELAY 5 CONTROL WATER VALVE 6 FLUSH TIMER 7 FLUSH SWITCH 8 FLUSH WATER VALVE 9 CONTROL 10 GEAR MOTOR RELAY 11 GEAR MOTOR 12 FAN MOTOR 1 COMPRESSOR 14 PRESSURE SWITCH Miswiring Circuit Protect Relay operates Proper wiring The unit starts BIN CONTROL OFF ON 1 1111 AH LOW WATER FLUSH TIMER CIRCUIT PROTECT ON RELAY OFF 22 2 cs pen i OFF OTE SWITCH ON OFF So 11 11 4 WATER CONTROL RELAY OFF CONTROL WATER ON VALVE OFF T H 6 FLUSH TIMER 22 FLUSH SWITCH 8 FLUSH WATER VALVE BIN CONTROL 0 GEAR MOTOR 11 GEAR MOTOR 12 FAN MOTOR COMPRESSOR 4 PRESSURE SWITCH m a 26 ON OFF BN z T 1 ON OFF FLUSH SWITCH PRESSURE SWITCH FLUSH ICE OFF ON OF
19. T 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 Unplug the icemaker Remove the panels Recover the refrigerant and store it in an approved container if required by an applicable law Remove the drier using brazing equipment 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 PSIG when brazing the tubings Check for leaks using nitrogen gas 140 PSIG and soap bubbles Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge and type Replace the panels in their correct position Plug in the icemaker 38 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 valv
20. been filled gear motor starts immediately BK BLACK 0 ORANGE BROW P PIN DX BLE E 115 12016011 18 W WHITE Y YELLOW power y WITCH 9 STARTER 7 73 RUN 2 T PROTECTOR 6 427 FLUSH WATER VALVE CIRCUIT PROTECT RELAY CONDENSER FAN AIR COOLED MODEL ONLY 16 Compressor starts about 60 sec after gear motor starts BK BLAK 00086 BR BROW 115 120 60 1 BLUE WHITE T YELLOW N BR W MITH S RUN CAP 258 FLUSH TIMER TS Q aR MOTOR 1209 AIR COOLED MODEL ONLY 17 d control operates and about 6 sec later compressor and gear motor stop simultaneously BLACK 0 ORANGE BR BROWN P PINK DBU DARK BLUE 8 48 Gf GRAY V VIOLET LBU LIGIT BLUE W WHITE Y YELLOW 115 120160 1 CONTROL TIMER eS an ROL DO R P ND ar 9 e 22 14 rd ET 0 004 RAP x TURA 08 HOTOR RELAY 18 Low water except water cooled model BK BLACK 0 ORANGE BR BROWN P PINK DBU DARK BLUE R RED GY GRAY Y 115 120 60 1 LBU LIGHT BLUE WHITE Y N PER N WITCH 9 TART STARTER Lc L
21. ced 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 12080 8 Nes zat terc 4 DM F4A50MAH I RR 4 citer me M M LUCI Ma RASEN e Ee OI M 5 1 General ater tar ene meen EO SERT 6 Mee SIR hehe neum 6 2 Control Box Layout spriti eee eee en EM NE 7 SANTI rr 8 3 Solid State 8 pee e rec NE 8 9 o a 12 1 Water Circuit and Refrigeration 12 2 Wiring Diagram 13 1511 F 450MAH 13 b F 450MAH et NR M M 14 3 Sequence of Electrical 15 25 Data ut 28 lal F 450MAH Lo neuste siste ui Dam alu 28 D ES Gaerne er sere tee tee tare beret 29 V S rice Diagnosis eee er oe Po ee Oe eee 30 js WO RR 30 2 OW TGS
22. e all parts in their correct positions IMPORTANT When installing the baffles make sure that the bent surface the one without the studs faces the actuator so that the bent surface can guide the ice to the center of the actuator 15 Move the flush switch to the ICE position then turn on the power supply Replace the top panel and 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 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 5 Remove the strap connecting the spout to the chute assembly 6 Remove the thumbscrews securing the spout and lift it off 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 Replace the spout and strap 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 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 o
23. e 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 secure 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 39 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 Remove the three socket head cap screws and lift off the extruding head 8 Replace the bearing inside the extruding head if it exceeds the wear tolerance of 0 02 or is scratched Note Replacing the bearing requires a bearing press adaptor If it is not available replace the whole extruding head Auger 9 Lift out the auger If the area in contact with the bearing is
24. f 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 48 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 and 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 the reservoir is empty 49 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
25. he control water valve Inlets and remove the control water valve Do not lose the packings inside the fitting nut 42 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 9 Removal and Replacement of Flush Water Valve 1 Turn off the power supply 2 Remove the panels 3 Close the water supply line shut off valve 4 Remove the clamp and disconnect the hose from the flush water valve that attaches to the evaporator Note Water may still remain inside the evaporator Be sure to drain the water into the drain pan 5 Disconnect the flush water valve from the tube connected to the plastic tee leading to the drain hose 6 Disconnect the terminals from the flush water valve 7 Remove the flush water valve from the frame or bracket 8 Connect the new flush water valve back onto the frame or bracket 9 Connect the tube from the plastic tee to the new flush water valve 10 Connect the hose to the flush water valve and secure it with the clamp 11 Pour water into the reservoir and check for water leaks on the flush water valve 12 Open the water supply line shut off valve 13 Turn on the power supply 43 14 Move the flush switch to the ICE positi
26. ing worn out damaged Evaporator Low side pressure Seeif Expansion too low Valve Bulb is mounted properly and replace the valve if necessary 2 Scale on inside wall Remove Auger Use of Freezing Cylinder SCALE AWAY or LIME A WAY solution to clean periodically If the water is found hard by testing install a softener 2 Overflow from Install a pressure Reservoir Water Reducing Valve close and replace Gear Motor Fuse a Power Supply 1 Too high or too low 1 Connect the unit to a breaker trips proper voltage worn out Auger Bin Control Doe cg contacts Check for continuity and replace Horis M Activator does not Clean Axle and its move freely corresponding holes or replace Bin Control 34 V Removal and Replacement of Components 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
27. 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 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 5 Disconnect the vacuum pump and attach a 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 35 6 A liquid charge is recommended for charging 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
28. on 15 Check for water leaks 16 Move the flush switch to the FLUSH position and make sure water is flushing 17 Move the flush switch to the ICE position 18 Replace the panels in their correct position VI 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 the 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 closed 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 Shut off Valve 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 Drain Valve 7 Turn off the power supply Air CO2 8 Turn off the power switch on the control box 44 9 Replace the front panel in its correct position 10 Close the drain valve 11 Remove all ice from the storage bin and clean
29. 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 exposed 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 connec tions before unbrazing the components Use a good abrasive cloth to remove coating 36 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
30. rts 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 Replace the spout and strap 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 front panel 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 front panel and turn off the power supply 19 Drain out all water from the water line See 4 through 6 46 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 19 1 of warm water IM
31. 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 Technical Information 1 Water Circuit and Refrigeration Circuit CONTROL oo SPOUT VALVE 9 FLOAT SWITCH WATER RESERVOIR NM OVERFLOW EXPANSION VALVE i A Ci y FLUSH WATER VALVE DRAIN PAN CONDENSER PRESSURE 2 55 VALVE VALVE COMPRESSOR WATER CIRCUIT REFRIGERANT CIRCUIT 12 2 Wiring Diagram BK BLACK 0 ORANGE BR BROWN P PINK a F 450MAH DU ME RE 115 120 60 1 LU LIGIT BLUE W WHITE T YELLOW N afo STARTER START A RUN 254A WITCH FLUSH BR FLUSH WATER VALVE CIRCUIT PROTECT RELAY CONTROL THER PROTECTO
32. sensor inside the ice chute can be accessed by opening the bin door and reaching into the chute from below the ice machine Clean the sensor using a neutral cleaner on a clean soft cloth at least twice a month 51
33. ss adaptor If it is not available replace the whole bearing lower 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 41 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 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 and 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 t
34. tant 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 1 2 EN G4FN 11127P 8 DC24V DC24V e qe 01 e o BUM bb 4000 4017 em ag 02 12 21 Fig 1 c Sequence 24VAC 50 60H2 CONTROL CTL PROTECT PRT X1 RELAY GEAR MOTOR X2 RELAY COMPRESSOR PART CODE MODEL RATING T1 T2 T3 T4 T5 T6 437305 01 2 144 01 24 50 60 2 60 15 sec 90 22 sec 150 45 1 sec or less 6 7 sec 70 6 7 sec 70 Fig 3 10 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
35. the bin 2 Cleaning and Sanitizing Instructions WARNING 1 HOSHIZAKI recommends cleaning this unit at least twice 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 LIME A WAY Economics Laboratory Inc with 0 8 gallons 3 1 of warm water This is a minimum amount Make more solution if necessary IMPORTANT For safety and maximum effectiveness use the solution immediately after dilution 45 b Cleaning Procedure The cleaning process will remove lime deposits from the water system 1 Remove the front panel and top panel then turn off the power supply 2 Close the 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 7 Remove the strap connecting the spout to the chute assembly 8 Remove the thumbscrews securing the spout and lift it off 9 Pour the cleaning solution over the extruding head until the evaporator assembly and the reservoir are filled and the solution sta
36. 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 50 3 Air Filter A plastic mesh air filter removes dirt or dust from the air and keeps the condenser 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 5 Infrared Sensor C model only The infrared
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