Hoshizaki F-300BAF manual

Hoshizaki “A Superior Degree of Reliability” www .hoshizaki.com Model F-300BAF Self-Contained Flaker Hoshizaki America, Inc. Number: 73072 Issued: 3-2-1999 Revised: 01-25-2007 S E RV I C E M A N U A L[...]

2 IMPOR T ANT Only qualified ser vice technicians should attempt to ser vice or maintain this unit. No such ser vice or maintenance should be under taken until the technician has thoroughly read this Ser vice Manual. HOSHIZAKI provides this man ual primar ily to assist qualified ser vice technicians in the ser vice and maintenance of the unit. Sh[...]

3 Please re vie w this manual. It should be read carefully bef ore the unit is ser viced or maintenance operations are perf or med. Only qualified ser vice technicians should ser vice and maintain the unit. This manual should be made a vailab le to the technician prior to ser vice or maintenance. CONTENTS I. Specifications .......................[...]

4 V . Remov al and Replacement of Components .................................................................... 33 A. Ser vice for Refrigerant Lines ...................................................................................... 33 1. Refr igerant Reco v er y .................................................................................[...]

5 I. Specifications A. Icemaker 1. F-300BAF Note: We reserve the right to make changes in specifications and design without prior notice. AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 9.0 A ( AT 104°F/ WT 80°F ) MINIMUM CIRCUIT AMPACITY N/A MAXIMUM FUSE SIZE N/A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day [...]

6 II. General Information A. Construction 1. F-300BAF *The s witch actuator is located in the ice storage bin. Ice Storage Bin Sliding Door Control W ater V alv e Reser v oir Expansion V alve Control Bo x Air-cooled Condenser Bin Control * Spout Ev aporator Gear Motor Compressor[...]

7 B. Ice Making Unit[...]

8 C. Control Bo x La y out 1. F-300BAF a) A uxiliary Code K-1 and Earlier Note: The abov e component names are identical with the wir ing label, but not with the par ts list. FLUSH SWITCH PO WER SWITCH CONTROL BO ARD FUSE (1A) GEAR MO TOR FUSE (1.5A) TRANSFORMER CAP ACIT OR - GEAR MO TOR ST ART CAP ACIT OR FLUSH RELA Y PRESSURE SWITCH W A TER CONTR[...]

9 c) A uxiliary Code L-1 and M-0 FLUSH SWITCH PO WER SWITCH CONTROL BO ARD FUSE (1A) GEAR MO TOR FUSE (1.5A) TRANSFORMER CAP ACIT OR - GEAR MO TOR ST ART CAP ACIT OR FLUSH RELA Y PRESSURE SWITCH W A TER CONTROL RELA Y GEAR MO TOR PRO TECT RELA Y CONTROL TIMER d) A uxiliary Code M-1 and Later FLUSH SWITCH PO WER SWITCH CONTROL BO ARD FUSE (1A) GEAR [...]

10 D . Timer Board 1. Solid-State Timer Board Contr ol • A HOSHIZAKI e xclusiv e solid-state sequence timer board is emplo yed in Hoshizaki self- contained flaker icemak ers. • All models are pre-tested and f actor y-adjusted. CA UTION 1. F ragile , handle v er y carefully . 2. The timer board contains CMOS (Complementar y Metal-Oxide Semicond[...]

11 E. Sequence of Operation Hoshizaki utilizes a solid state timer board to s witch the components on and off as needed. The sequence is as follo ws: 1. Star tup Flush s witch in "ICE" position, po wer s witch in "ON" position. FR energizes . 2. Fill Cycle WV opens and the reser v oir fills with water until UF/S closes . Note: [...]

12 Legend: BC - bin control Comp - compressor FMS - self-contained f an motor FR - flush rela y FWV - flush water v alve GM - gear motor GMPR - gear motor protect rela y LF/S - low er float s witch TC - timer control UF/S - upper float s witch WCR - water control rela y WV - inlet water v alve UF/S open LF/S open 90 sec. TC star ted WCR de-ener[...]

13 III. T echnical Inf ormation A. W ater Cir cuit and Refrigeration Circuit F-300B AF[...]

14 B. Wiring Diagram 1. Auxiliary Code K-1 and Earlier F-300BAF[...]

15 2. Auxiliary Code K-2 and L-0 F-300BAF[...]

16 3. Auxiliary Code L-1 and M-0 F-300BAF[...]

17 4. Auxiliary Code M-1 and Later F-300BAF[...]

18 C. Sequence of Electrical Circuit 1. Fill Cycle When pow er s witch is mo v ed to "ON" position, water is supplied to reser voir . F-300BAF[...]

19 2. Ice Purge Cycle When reser v oir has filled, gear motor star ts. F-300BAF[...]

20 3. Freez e Cyc le Compressor and condenser f an motor star t about 60 sec. after gear motor star ts . F-300BAF[...]

21 4. Shutdown Compressor and condenser f an motor stop about 90 sec. after bin control operates, gear motor stops about 60 sec. later . Flush water v alv e then operates . F-300BAF[...]

22 5. Cleaning - Flush Switch Compressor and condenser f an motor stop about 90 sec. after manually moving flush s witch to FLUSH position. Gear motor stops about 60 sec. later . Flush water v alv e then operates . F-300BAF[...]

23 6. Low W ater Safety If upper float s witch f ails to close, water v alve remains open until upper float s witch closes and water control rela y energizes . F-300BAF[...]

24 7. Spout Safety Switch When saftey s witch is activ ated, the saf ety s witch relay oper ates, and the icemak er does not run. F-300BAF[...]

25 8. High Pressure Switch In case of high pressure, pressure s witch shuts down unit. F-300BAF[...]

26 D . P erformance Data 1. F-300BAF APPROXIMATE Ambient W ater Tem p. (°F) ICE PRODUCTION Tem p. (°F) PER 24 HR. 70 *303 *(137) 290 (131) 278 (126) 80 267 (121) 256 (116) 246 (112) 90 236 (107) *232 *(105) 218 (99) lbs./day (k g/day ) 100 209 (95) 201 (91) * 188 *(85) APPROXIMATE ELECTRIC 70 *667 -- 668 -- 669 -- CONSUMPTION 80 670 -- 671 -- 672[...]

27 IV . Ser vice Diagnosis A. Diagnostic Pr ocedure This diagnostic procedure is a sequence check that allo ws you to diagnose the electrical system and components under nor mal operating conditions of 70°F or w armer air and 50°F or warmer water temperatures . Bef ore proceeding, check f or correct installation, proper v oltage per unit nameplat[...]

28 5) Refill/Low Water Saf ety Cycle – As ice is produced, the water le vel in the reservoir drops. As it drops, the upper float s witch and lower float s witch open. The upper float s witch opens first. Nothing occurs at this time. When the lo wer float s witch opens, the refill begins. The water control rela y de-energizes, the lo w wate[...]

29 B. Diagnostic Charts 1. No Ice Production Prob lem P ossible Cause Remedy [1] The icemaker will not star t. (fill cycle, water valv e) a) P ower Supply 1. Off . 1. T ur n on. 2. P ower cord unplugged. 2. Plug into receptacle. 3. Loose connection. 3. Tighten. 4. Bad contacts. 4. Check f or contintinuity and replace. 5. Blown fuse . 5. Replace. b[...]

30 Prob lem P ossible Cause Remedy j) W ater Control Relay 1. Bad contacts. 1. Replace. 2. Open coil. 2. Replace. k) W ater V alve 1. Coil winding opened. 1. Replace. l) Shut-off V alve 1. Closed. 1. Open. 2. W ater failure. 2. W ait until water is supplied. m) Plug and Receptacle (Control Bo x) 1. Disconnected. 1. Connect. 2. Loose terminal. 2. Re[...]

31 Prob lem P ossible Cause Remedy e) Compressor 1. Loose connections. 1. Tighten. 2. Motor winding opened or grounded. 2. Replace. 3. Compressor lock ed and motor protector tripped. 3. Replace compressor . f) P ower Supply 1. Circuit ampacity too low . 1. Install a larger-siz ed circuit. [5] Gear motor and compressor star t, but no ice is produced[...]

32 3. Other Prob lem P ossible Cause Remedy [1] Abnormal noise a) F an Motor 1. Bearing wor n out. 1. Replace. 2. F an blade def ormed. 2. Replace f an blade . 3. F an blade does not mov e freely . 3. Replace. b) Compressor 1. Bearings wor n out, or cylinder v alve brok en. 1. Replace. 2. Mounting pad out of position. 2. Reinstall. c) Refrigerant L[...]

33 V . Remov al and Replacement of Components IMPOR T ANT Ensure all components, f asteners and thumbscrews are securely in place after the equipment is ser viced. IMPOR T ANT 1. The P olyol Ester (POE) oils used in R-404A units can absorb moisture quickly . Theref ore it is impor tant to pre v ent moisture from entering the system when replacing o[...]

34 8) If necessar y , add any remaining charge to the system through the lo w-side. Use a throttling v alv e or liquid dispensing de vice to add the remaining liquid charge through the low-side access por t with the unit running. 9) Close the two refrigerant access v alv es , and disconnect the ser vice manif old hoses . 10) Cap the access v alv es[...]

35 C. Remov al and Replacement of Compressor IMPOR T ANT Alwa ys install a new drier e v er y time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made. Note: When replacing a compressor with a defectiv e winding, be sure to install the new start capacitor and star t rela y su[...]

36 D . Remo v al and Replacement of Drier IMPOR T ANT Alwa ys install a new drier e v er y 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 unit from the electrical outlet. 2) Remov e the panels. 3) Recov er the refr igerant and store it in an appro v e[...]

37 8) Check f or leaks using nitrogen gas (140 PSIG) and soap bub b les. 9) Ev acuate the system, and charge it with refrigerant. See the nameplate for the required refrigerant charge. 10) Attach the e xpansion v alv e bulb to the suction line in the same location as the pre vious bulb . The bulb should be at the 12 o'cloc k position on the tu[...]

38 F . Remov al and Replacement of Ev aporator Assembl y Components CA UTION Make sure that the safte y switch and spout are properly installed after making repairs in the e v aporator assemb ly . F ailure to install the safety s witch and spout correctly could result in serious damage to the unit. Fig. 1 Drip Brack et Saf ety Br ac ket A Saf ety B[...]

39 1. Upper Bearing W ear Chec k T o ensure that the bear ing inside the e xtr uding head does not e xceed the wear toler ance of .02", f ollo w the instructions below . 1) Unplug the unit from the electrical outlet. 2) Remov e the panels. 3) Remov e the thumbscrews and tak e off the spout from the e v aporator . 4) Loosen the cutter with a wr[...]

40 3. Remov al and Replacement of Extruding Head 1) Unplug the unit from the electrical outlet. 2) Remov e the panels. 3) Remov e the thumbscrews and tak e off the spout from the e vaporator . 4) Loosen the cutter with a wrench and remov e it. 5) Remov e the allen head cap screws and lift off the e xtr uding head. 6) Place new e xtruding head in pl[...]

41 4) Recov er the refr igerant and store it in an appro v ed container . 5) Remov e the thumbscrews and tak e off the spout from the e vaporator . 6) Disconnect the water hoses . 7) Remov e the allen head cap screws securing the e xtruding head. Using the cutter , lift out the auger assembly . 8) Remov e the insulation and the expansion v alve b u[...]

42 7) Remov e the allen head cap screws securing the e v aporator to the lo wer bearing housing. 8) Raise the e v aporator up to access the lo wer housing. 9) Remov e the O-r ing and mechanical seal from the housing. If only replacing mechanical seal, proceed to step 12). W ARNING T o help pre v ent water leaks , be careful not to damage the surf a[...]

43 10) Replace the panels in their correct positions. 11) Plug the unit back in. G. Remov al and Replacement of Fan Motor 1) Unplug the unit from the electrical outlet. 2) Remov e the panels. 3) Remov e the wire connectors from the fan motor leads . 4) Remov e the fan motor br ac ket and f an motor . 5) Install the new f an motor . 6) Replace the f[...]

44 8) Connect the hose to the water v alve and secure it with the clamp . 9) P our water into the reservoir , and check f or water leaks. 10) Open the water supply line shut-off v alve . 11) Plug the unit back in. 12) Mov e the flush switch to the "ICE" position. 13) Check f or water leaks . 14) Mov e the flush switch to the "FLUSH[...]

45 VI. Cleaning and Maintenance IMPOR T ANT Ensure all components, f asteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. A. Cleaning and Sanitizing Instructions W ARNING 1. HOSHIZAKI recommends cleaning this unit at least once a year . More frequent cleaning, how e v er , ma y be required in so[...]

46 8) Remov e the thumbscrews attaching spout (A) to the e v aporator assemb ly and lift off spout (A) and spout packing (A). See Fig 4. 9) P our the cleaning solution ov er the e xtruding head until the e v aporator assembly and the reservoir are filled and the solution star ts to ov erflo w into the drain pan. Note: If there is e xcess scale on[...]

47 4. Sanitizing Procedure - Initial 1) Close the water supply line shut-off v alve . 2) In the storage bin, remo v e the thumbscre ws attaching spout (B), then remov e spout (B) and spout packing (B). 3) Remov e the thumbscrews attaching spout (A) to the e vaporator assemb ly and lift off spout (A) and spout packing (A), and the cylinder pac king.[...]

48 8) Using the thumbscrews , replace spouts (A) and (B) and spout packings (A) and (B) in their correct positions. 9) Allow the icemak er to sit for about 10 min utes bef ore operation. 10) Mov e 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. [...]

49 B. Maintenance IMPOR T ANT 1. This icemaker must be maintained individually , referring to the instruction manual and labels pro vided with the icemak er . 2. T o hav e the optimum unit perf ormance, the f ollowing par ts need periodic inspection and maintenance: Extruding Head and Upper Bear ing Housing and Low er Bearing Mechanical Seal A uger[...]

50 C. Preparing the Icemaker for Long Stora ge W ARNING When shutting off the icemaker f or an e xtended time, dr ain out all water from the water line and remo v e the ice from the storage bin. The storage bin should be cleaned and dried. Drain the icemak er to pre v ent damage to the w ater supply line at sub-freezing temperatures , using air or [...]