Hoshizaki F-801MAH/-C manual

SER VICE MANUAL June 7, 2004 MODEL HOSHIZAKI MODULAR FLAKER F-801MAH/-C F-801MWH/-C 73113 June 15, 2005 ISSUED: NO: REVISED:[...]

2 IMPORT ANT 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 [...]

3 CONTENTS I. Specification ............................................................................................................... ....... 5 1. Icemaker ....................................................................................................................... 5 F-801MAH .........................................................[...]

4 5. Remov al and Replacement of Expansion V alv e ......................................................... 43 6. Remov al and Replacement of W ater Regulating V alv e (water-cooled model only) .... 44 7. Removal and Replacement of Evaporator Assembly ................................................. 4 5 8. Remov al and Replacement of F an Motor .[...]

5 I. Specification 1. Icemaker F-801MAH We reserve the right to make changes in specifications and design without prior notice. AC SU PPL Y VOL T AG E 1 15 /60 /1 COM P RE S S OR 120 V 9. 4 RLA 51 LRA G EAR MO T O R 1 2 0 V 3 FL A 1 /4 H P FA N M OT OR 115 V 0.85 F LA 1/ 15 HP OT HE R 120 V 0.03 A MAX I MU M FU SE SI Z E 2 0 A MAX . H AC R BREAKER [...]

6 F-801MWH We reserve the right to make changes in specifications and design without prior notice. AC SU PPL Y VOL T AGE 1 1 5 /60 /1 COMP RE S S OR 120 V 8.5 RLA 5 1 LRA G EAR MO T O R 1 2 0 V 3 FL A 1 /4 H P OT HE R 120 V 0. 03 A MAX I MUM F U SE SI Z E 20 A MAX . H AC R BR EAKER ( U SA ON L Y) 2 0 A MAX . C I R C . BR EAKER ( C AN AD A O N L Y) [...]

7 F-801MAH-C We reserve the right to make changes in specifications and design without prior notice. AC SU PPL Y VOL T AGE 1 1 5 /60 /1 COMP RE S SOR 120 V 9.4 RLA 51 L RA G EAR MO T O R 1 2 0 V 3 FL A 1 /4 H P FA N MO T O R 115 V 0. 8 5 FL A 1/ 15 HP OT HE R 120 V 0. 03 A MAX I MUM F U SE SI Z E 20 A MAX . H AC R BR EAKER ( U SA ON L Y) 2 0 A MAX [...]

8 F-801MWH-C We reserve the right to make changes in specifications and design without prior notice. AC SU PPL Y VOL T AGE 1 1 5 /60 /1 COM P RE S S OR 120 V 8. 5 RLA 51 LRA G EAR MO T O R 1 2 0 V 3 FL A 1 /4 H P OT HE R 120 V 0.03 A MAX I MU M FU SE SI Z E 2 0 A MAX . H AC R BREAKER ( U SA ON L Y) 2 0 A MAX . C I R C . BR EAKE R ( C AN AD A ON L Y[...]

9 II. General Information 1. Construction F-801MAH/-C Water Supply Inlet Junction Box Condenser Fan Motor Compressor Drier Control Water Valve Bin Control Ice Chute Evaporator Expansion Valve Flush Water Valve Control Box Gear Motor[...]

10 F-801MWH/-C Water Supply Inlet Junction Box Water Regulator Compressor Drier Control Water Valve Bin Control Ice Chute Evaporator Expansion Valve Flush Water Valve Control Box Gear Motor[...]

11 2. Control Bo x Lay out F-801MAH/-C Note: The above component names are identical with the wiring label, but not with the parts list. PRESSURE SWITCH CONNECT OR ST ART CAP ACIT OR RUN CAP ACIT OR W A TER CONTROL RELA Y FLUSH TIMER TRANSFORMER GEAR M OTOR RELA Y GEAR M OTOR CAP . FLUSH ICE FA N M OTOR CAP GEAR MO TOR PRO TECT RELA Y ST ARTER CONT[...]

12 F-801MWH/-C PRESSURE SWITCH CONNECT OR ST ART CAP ACIT OR RU N CAP ACIT OR W A TER CONTROL RELA Y TRANSFORMER GEAR M OTOR RELA Y FLUSH ICE GEAR MO TOR PRO TECT RELA Y ST ARTER CONTROL TIMER FLUSH SWITCH PO WER SWITCH FUSE FUSE (GEAR MO TOR) FLUSH TIMER CIRCUIT PRO TECT RELA Y GEAR M OTOR CAP .[...]

13 III. T echnical Information 1. W ater Circuit and Refrigeration Cir cuit F-801MAH/-C[...]

14 F-801MWH/-C[...]

15 2. Wiring Diagrams F-801MAH/-C, F-801MWH/-C[...]

16 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.[...]

17 [b] When reservoir has been filled, gear motor starts immediately.[...]

18 [c] Compressor starts about 60 sec. after gear motor starts.[...]

19 [d] Bin control operates, and about 6 sec. later, compressor and gear motor stop simultaneously.[...]

20 [e] Low water (except water-cooled model).[...]

21 [f] Low water (water-cooled model), or dirty air filter (air-cooled model), pressure switch to “OPEN”, compressor and gear motor operate intermittently.[...]

22 [g] When flush switch is moved to “FLUSH” position, flush water valve opens and flushes reservoir and evaporator.[...]

23 [h] When flush timer operates (for 15 min. every 12 hours).[...]

24 [i] When 208-230V are supplied to circuit protect relay, it protects the circuit from miswiring. If the power supply is properly connected, the contact of circuit protect relay does not move even when the coil is energized.[...]

25 [j] When input voltage is too low, (less than 70%), gear motor fuse (1.5A) is blown causing the compressor and gear motor to turn off immediately.[...]

26 Miswiring. Circuit Protect Relay operates.) Proper wiring. The unit starts. BIN CONTROL OFF ON 1. CIRCUIT PROTECT RELA Y 2. W A TER LEVEL 3. FLOA T SWITCH UPPER LOWER 4. W A TER CONTROL RELA Y 5. CONTROL WA TER VA LV E 6. FLUSH TIMER 7. FLUSH SWITCH 8. FLUSH W A TER VA LV E 9. BIN CONTROL 10. GEAR MOTOR RELA Y 1 1. GEAR MOTOR 12. F AN MOTOR 13. [...]

27 1. CIRCUIT PROTECT RELA Y 2. W A TER LEVEL 3. FLOA T SWITCH UPPER LOWER 4. W A TER CONTROL RELA Y 5. CONTROL WA TER VA LV E 6. FLUSH TIMER 7. FLUSH SWITCH 8. FLUSH W A TER VA LV E 9. BIN CONTROL 10. GEAR MOTOR RELA Y 1 1. GEAR MOTOR 12. F AN MOTOR 14. PRESSURE SWITCH ON OFF ON OFF ON OFF ON OFF ON OFF 1 - 2 2 - 3 FLUSH ICE ON OFF ON OFF ON OFF O[...]

28 1. CIRCUIT PROTECT RELA Y 2. W A TER LEVEL 3. FLOA T SWITCH UPPER LOWER 4. W A TER CONTROL RELA Y 5. CONTROL WA TER VA LV E 6. FLUSH TIMER 7. FLUSH SWITCH 8. FLUSH W A TER VA LV E 9. BIN CONTROL 10. GEAR MOTOR RELA Y 1 1. GEAR MOTOR 12. F AN MOTOR 14. PRESSURE SWITCH ON OFF ON OFF ON OFF ON OFF ON OFF 1 - 2 2 - 3 FLUSH ICE ON OFF ON OFF ON OFF O[...]

29 5. Perf ormance Data F-801MAH We reserve the right to make changes in specifications and design without prior notice. APPR OX I MAT E Amb ie n t W a te r T e mp . ( F) I CE P ROD UC T I ON T emp. (F) P E R 24 H R. 70 * 823 (373) 7 86 (357) 748 (339) 80 711 (323) 677 (307 ) 644 ( 292) 90 613 (278) * 599 (272 ) 555 ( 252) l bs . / day ( k g/ day )[...]

30 F-801MWH We reserve the right to make changes in specifications and design without prior notice. APPR OX I MAT E Amb ie n t W a te r T e mp . ( F) I CE P ROD UC T I ON T emp. (F) P E R 24 H R. 70 * 720 (327) 6 93 (315) 677 (307) 80 661 (300) 646 (293 ) 630 ( 286) 90 616 (279) * 605 (274 ) 587 ( 266) l bs . / day ( k g/ day ) 100 573 (260) 560 (2[...]

31 F-801MAH-C We reserve the right to make changes in specifications and design without prior notice. APPR OX I MAT E Am b ie nt Wate r T e mp . ( F) I CE P ROD UC T I ON T emp. (F) P E R 24 HR. 70 * 752 (341) 728 (330 ) 68 8 (312) 80 650 (29 5) 6 14 (279) 580 (263) 90 54 8 (249) * 552 (250 ) 4 90 (222) l bs . / d ay (k g/ day ) 100 46 3 (210) 437 [...]

32 F-801MWH-C We reserve the right to make changes in specifications and design without prior notice. APPR OX I MAT E Amb ie n t W a te r T e mp . ( F) I CE P ROD UC T I ON T emp. (F) P E R 24 H R. 70 * 645 (293) 6 20 (281) 608 (276) 80 596 (270) 585 (265 ) 574 ( 260) 90 563 (255) * 550 (249 ) 541 ( 246) l bs . / day ( k g/ day ) 100 5 31 (241) 521[...]

33 IV . Adjustment of Components 1. Adjustment of W ater Regulating V alve (water -cooled model only) The water regulating valve or also called “water regulator” is factory-adjusted. No adjustment is required under normal use. Adjust the water regulator , if necessary, using the following procedures. 1) Attach a pressure gauge to the high-side [...]

34 2. Adjustment of Flake Size To adjust the flake size, change the direction of the cutter head on the top of the auger, according to the following procedures: 1) Remove the bolt and the cutter head. 2) The cutter head has two holes, one for fine flake and the other for coarse flake size. The unit is shipped from the factory in the fine flake posi[...]

35 V . Service Diagnosis 1. No Ice Production PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker will not start. a) Power Supply 1. OFF position. 1. Move to ON position. 2. Loose connection. 2. Tighten. 3. Bad contacts. 3. Check for contintinuity and replace. 4. Blown fuse. 4. Replace. b) Power Switch (Control Box) 1. Off position. 1. Move to ON positi[...]

36 PROBLEM POSSIBLE CAUSE REMEDY [4] Water has been supplied, Fan Motor starts, but Gear Motor and Compressor will not start. a) Gear Motor Fuse (BUSSMAN GMD 1.5A) 1. Blown Fuse. 1. See "3. [3]." Find out the cause and replace the Fuse. b) Thermal Protector (Gear Motor) 1. Bad contacts. 1. Check for continuity and replace. [5] Gear Motor [...]

37 2. Low Ice Production PROBLEM POSSIBLE CAUSE REMEDY [1] Low ice production a) Refrigerant Line 1. Gas leaks. 1. See "1. [5] a) Refrigerant Line." 2. Refrigerant line clogged. 2. Replace the clogged component. 3. Overcharged. 3. Recharge. b) High-side Pressure Too High 1. Dirty Air Filter or Condenser. 1. Clean. 2. Ambient or condenser [...]

38 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 does not move freely. 3. Replace. b) Compressor 1. Bearings worn out, or cylinder valve broken. 1. Replace. 2. Mounting pad out of position. 2. Reinstall. c) Refrigerant Lines 1. Rub or[...]

39 VI. Removal and Replacement of Components 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 d[...]

40 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 reclai[...]

41 3. Removal and Replacement of Compressor IMPORT ANT 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) Turn off the power supply, and remove the panels. 2) Remove the terminal cover on the compressor, and disconnect the compress[...]

42 14) Evacuate the system, and charge it with refrigerant. For the air-cooled and water-cooled models, see the nameplate for the required refrigerant charge and type. For the remote air- cooled models, see the label on the control box. 15) Connect the terminals to the compressor, and replace the terminal cover in its correct position. 16) Replace [...]

43 5. Remov al and Replacement of Expansion V alve IMPORT ANT 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) Turn o[...]

44 6. Remov al and Replacement of W ater Regulating V alve (water-cooled model only) IMPORT ANT 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) Turn off the power supply, remove the panels and close the water supply line shut-of[...]

45 7. Removal and Replacement of Evaporator Assembly 1) Turn off the power supply. 2) Remove the panels. 3) Move the flush switch to the "FLUSH" position. 4) Turn on the power supply and drain out all water from the water line. 5) Turn off the power supply. 6) Remove the strap connecting the spout to the chute assembly. 7) Remove the thre[...]

46 13) Recover the refrigerant and store it in an approved container, if required by an applicable law. IMPORT ANT 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. 14) Remove the bulb of the expansion valve. 15) Disconnect the brazi[...]

47 26) Assemble the removed parts in the reverse order of the above procedure. W ARNING 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. 27) When replacing the evaporator; (a) Braze the new evaporator with nitrogen gas flowin[...]

48 Auger Mechanical Seal O-ring Bearing - Lower Bolt Washer Coupling - Spline Rubber O-ring Nylon Ring Bolt Washer Cutter Extruding Head Washer Socket Head Cap Screw Evaporator Washer Socket Head Cap Screw Barrier Gear Motor[...]

49 8. Removal and Replacement of Fan Motor 1) Turn off the power supply and remove the panels. 2) Remove the wire connectors from the fan motor leads. 3) Remove the fan motor bracket and fan motor. 4) Install the new fan motor. 5) Replace the fan motor bracket and the wire connectors. 6) Replace the panels in their correct position, and turn on the[...]

50 10. Remov al and Replacement of Flush W ater V alve 1) Turn off the power supply, remove the panels and close the water supply line shut-off valve. 2) Remove the clamp and disconnect the hose from the flush water valve. Note: Water may still remain inside the evaporator. Be sure to drain the water into the drain pan. 3) Disconnect the terminals [...]

51 VII. Cleaning and Maintenance IMPORT ANT 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 W ARNING When shutting off the icemaker for an extended time, drain out all water from the water line and remove the ice from the st[...]

52 [Water-Cooled Models] 1) Turn off the power supply and wait for 3 minutes. 2) Turn on the power supply and wait for 20 seconds. 3) Close the water supply line shut-off valve. 4) Open the drain valve and quickly blow the water supply line from the drain valve to drain water in the condenser. 5) Follow the above steps 3) through 11) in [Air-Cooled[...]

53 [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 ou[...]

54 [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 (19 l) of warm water. IMPOR T ANT For safety and maximum effectiveness, use the solution immediately after dilution. [d] Sanitizing Procedure - Initial The sanitizing process will sanitize the i[...]

55 14) Replace all parts in their correct positions. IMPOR T ANT 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 pan[...]

56 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 bi[...]

57 3. Maintenance IMPOR T ANT 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 periodical inspection, maintenance and replacement: Extruding Head Housing Gear Motor Auger Mechanical Sea[...]

58 3) Air Filter (air-cooled model only) 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 (ex[...]