Hoshizaki FS-1022MLH-C manual

Hoshizaki “A Superior Degr ee of Reliability” www .hoshizaki.com Model FS-1022MLH-C Including Condensing Unit Model SRC-10H Modular Cubelet Serenity Series Hoshizaki America, Inc. Number: 73186 Issued: 6-9-2011 SE RV ICE MA NU AL[...]

2 IMPOR T ANT Only quali ed ser vice technicians should inst all, ser vice , and maintain the icemaker . No ser vice or maint enance should be under tak en until the t echnician has thoroughl y read this Ser vice Manual. F ailure t o ser vice and maintain the equipment in accordance with this man ual ma y adver sely af fect saf et y , perf orman[...]

3 IMPOR T ANT This manual should be r ead car efull y bef ore the icemak er is ser viced or maintenance oper ations ar e perf or med. Only quali ed ser vice technicians should install, service, and maintain the icemak er . Read the warnings contained in this booklet carefull y as they giv e impor tant inf or mation reg arding saf et y . Please r[...]

4 IV . Ser vice Diagnosis ........................................................................................................... 26 A. Ice P roduction Chec k .................................................................................................. 26 B. Diagnostic P rocedure ............................................................[...]

5 Impor tant Safety Inf ormation Throughout this man ual, notices appear t o bring your at tention t o situations which could result in death, serious injur y , or damage to the unit. W ARNING Indicates a hazardous sit uation which could r esult in death or serious injury . C A UTION Indicates a sit uation which could result in dama ge to the unit.[...]

6 F or FS - Continued • T oreducetheriskofelectr icshoc k,donott ouchtheplugorpow ers witchwith damp hands. •Donotuseaunitwithadamagedpow ercor d.  Thepowercor dshouldnotbe alter ed, jer k ed, b undled, weighed do wn, pinched, or tangled. Such [...]

7 AC SUPPLY VOLTAGE 115/60/1 GEAR MOTOR 120 V 3 FLA 1/4 HP OTHER 120 V 0.03A MAXIMUM FUSE SIZE 15 A MAX. HACR BREAKER (USA ONLY) 15 A MAX. CIRC. BREAKER (CANADA ONLY) 15 A MINIMUM CIRCUIT AMPACITY 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lb./day (kg/day) 70 *830 (380) 805 (365) 785 (355) Reference wit[...]

8 Note: We r eser v e the r ight t o make changes in specications and design without prior notice. B. Condensing Unit 1 . SRC-1 0H AC SUPPLY VOLTAGE 208-230/60/1 (3 Wire w/Neutral for 115VAC) COMPRESSOR 208-230V 9.6 RLA 46 LRA FAN MOTOR 120 V 3 A MAX OTHER 120 V 0.5 A MAXIMUM FUSE SIZE 20 A MAX. HACR BREAKER (USA ONLY) 20 A MAX. CIRC. BREAKER (C[...]

9 II. General Inf ormation A. Construction 1 . Icemak er a) FS-1 022MLH-C Inlet W ater V alv e Reservoir Contr ol Bo x Mechanical Backup Bin Contr ol Spout Float Switch Gear Motor Thermostatic Expansion V alve Ice Chute Infrar ed Sensor Icemaking Unit: Cut ter Extruding Head Ev aporat or P ower C ord Drain V alv e P ump-Down Solenoid V alve High-Si[...]

10 2. Condensing Unit a) SRC-1 0H Condenser Receiv er F an Motor Headmaster (C .P .R.) High-Side Ser vice V alv e Compr essor High-P ressur e S witch Liquid Line Connection Suction Line Connection Contr ol Low -P r essur e S witch Contr ol Bo x Saf et y Low -P ressur e Switch[...]

11 3. Icemaking Unit Cut ter Extruding Head Upper Bearing Ev aporat or Heater A uger Mechanical Seal O-Ring Housing-Low er Bearing Spline Coupling Gear Motor He x Bolt and Washer Evapor at or Seal Bolts and Washer s Sock et Head Cap Scre w and Split Lock W asher W asher Sock et Head Cap Scre w and Split Lock W asher[...]

12 B. Sequence of Operation The steps in the sequence ar e as outlined below . This unit utilizes a contr ol boar d t o s witch the icemak er components on and of f as needed. When po wer is supplied, the pow ers witchisinthe"ON"position,andthecontrols witchisinthe"ICE"position, co[...]

13 d) Drain Cy cle (1) 1 -in-1 Drain Cy cle: D V energizes f or 2 seconds once e v er y hour when the 1 -in-1drain cycle is activ ated (S1 dip s witch 4 in the of f position (f actor y def ault position)). 1 -hour drain cy cle timer t erminates, 2-second DT st ar ts. D V energiz es f or 2seconds. 2-second DT terminates , 1 -hour DT resets . A[...]

14 e) Shutdown Cycle (1) Infrar ed Sensor: W hen pow er is supplied t o the icemak er , the green LED on IS tur ns on. The green LED r emains on constantly . As ice lls the stor age bin t o the le v elofactivatingIS ,ISy ellowLEDturnson( ashingorst eady).  TheyellowLED  asheswheniceis?[...]

15 1 -in-1 drain cy cle. D V opens for 2 seconds e very hour (S1 Dip Switch 4). "F-A" Contr ol Board Sequence Flow Chart FS-1 022MLH-C/SRC-1 0H LF/S closed UF/S closed FT terminates WV de-energiz es 3. 1 -in-12 Dr ain Cycle & Restart (optional) 3 . Icemaker Of f UF/S open LF/S open FT starts (90 sec.) WV energiz es Comp continues EH c[...]

16 C. Control Boar d • A Hoshizaki e x clusive contr ol board is emplo yed in Hoshizaki Modular Flak er s. • All models are pr e-test ed and f actor y set. C A UTION 1 . The control boar d is fragile; handle very carefull y . 2. The control board cont ains int egr at ed cir cuits, which ar e susceptible t o f ailure due to st atic dischar ge . [...]

17 "F-A" Contr ol Board "F-A" Contr ol Boar d P ar t Number 2A4296-0 1 • "FLUSH" LED (X3 Rela y) Drain V alv e • "COMP" LED (X1 Rela y) P ump-Down Solenoid V alve • "GM" LED (X2 Rela y) Gear Motor Evapor ator Heat er • K1 Connector (1 15V A C) #3 1 1 5V AC Input #2 Gear Motor , Evapor [...]

18 2. LED Lights and Audib le Alarm Saf eties The"PO WEROK"LEDindicat espr opercontr olv oltageandwillr emainonunlessa controlv oltagepr ob lemoccurs . F orfur therdetails,see"II.B . SequenceofOperation." Sequence Step LED Energized Components Min. Max. F[...]

19 3. Controls and Adjustments C A UTION Dip s witches ar e f actor y set. F ailure t o maintain f actory set tings ma y adver sel y af fect perf or mance and warr anty cov erage . F or mor e inf ormation, contact Hoshizaki T echnical Suppor t at 1 -800-233-1 940. a) Default Dip S witch Set tings The S1 dip s witch set tings are f actory -set t o t[...]

20 c) Drain F requenc y Control (S1 dip switch 4) This unit is f act or y set f or optimum perf ormance with the 1 -in-1 drain cy cle (S1 dip s witch4inthe"OFF"position).  Thisset tingallo wsf orremov alofsedimentfromthe e v aporator without int err upting the icemaking process . An optional 1 [...]

21 f) Mechanical Bin Contr ol Shutdown Delay (S1 dip switch 8) F actory set for normal operation. No adjustment is requir ed. The shutdown dela y is the time bet ween the mechanical bin contr ol pr o ximity switch opening and the contr ol board shut ting of f the icemak er . S1 Dip S witch Set ting Mechanical Backup Bin Control Shutdown Dela y No. [...]

22 III. T echnical Infor mation A. W at er Cir cuit and R efr igeration Cir cuit 1 . FS-1 022MLH-C with SRC-1 0H Over ow Reservoir Gear Motor Drain Va l v e Expansion V alve W ater Le v el Ev aporat or Float Switch Inlet W ater Va l v e W ater Supply Line Liquid Line Drier P ump-Down Solenoid V alve FS-1 022MLH-C SRC-1 0H Drain Outlet Compr esso[...]

23 B. W iring Diagr ams 1 . FS-1 022MLH-C[...]

24 2. SRC-1 0H * *** High-Pr essure Switc h Cut-out 384± 22 PSIG Cut-in 284±22 PSIG 0 ** *** ** Safety Lo w-Pr essure Switc h (Manual R eset) Cut-out 3±2.5 PSIG Dif fer ential 6 PSIG * Control Lo w-P ressur e Switch Cut-in 29± 0 PSIG Dif fer ential 20± 1 .0 PSIG Cut-out 9 PSIG 0.5 0.5[...]

25 C. P erf ormance Data 1 . FS-1 022MLH-C with SRC-1 0H Note: We r eser v e the r ight t o make changes in specications and design without prior notice. APPROXIMATE Ambient Water Temp. (F) ICE PRODUCTION Temp. (F) PER 24 HR. 70 *832 378 803 365 784 356 80 765 347 747 340 729 331 90 712 324 *703 320 679 309 lbs./DAY ( l/day ) 100 663 301 647 294[...]

26 IV . Service Diagnosis W ARNING 1 . This unit should be diagnosed and repair ed only b y quali ed ser vice personnel t o reduce the risk of death, electr ic shoc k, serious injur y , or re . 2. Risk of electr ic shock. Use e xtreme caution and e x ercise saf e electr ical practices . 3. Moving par ts (e.g ., f an blade) can crush and cut. [...]

27 K8connector pin #1 whit e/red (W/R) t o pin #2 light b lue (LBU). If 24V A C is not pr esent and 1A 24V A C fuse is good, replace the control tr ansf or mer . If 24V A C is present and "PO WEROK"LEDisof f ,CBisbadandmustber eplaced.  IS Diagnosis : CheckthatISgr eenLEDison. ?[...]

28 8) F r eeze Cyc le – "GM" and "COMP" LEDs are on . "GM"LED ,GMR(X2onCB), GM,GMPR,andEHcontinue . "COMP"LEDtur nsonandPDSenergiz es . Oncethe refrigeration cir cuit low-side pr essure rises to 29 PSIG, CLPS closes , ener gizing MC , which ener[...]

29 9) Re ll Cyc le/Low W ater Safety Cy c le – "GM", "COMP", and "WTRIN" LEDs are on. As ice is produced, the w ater le vel in the r eser v oir drops. UF/S opens. Nothing happens at this time. When LF/S opens, WV energizes , 90-second low wat er saf et y timer (ll timer) star ts. GMR (X2 on CB), GM, GMPR, EH, P[...]

30 C. Control Boar d Check Bef or e r eplacing a contr ol boar d that does not show a visib le defect and that y ou suspect is bad, alw ay s conduct the follo wing chec k pr ocedur e. This procedur e will help you v erify your diagnosis . Befor e proceeding , chec k f or pr oper v oltage per unit nameplate . Check that the 24V A C 1A fuse and the 1[...]

31 4) 5VDC Output Checks: C ontrol S witch (open contacts f or icemaking, closed cont acts f or drain), GMPR (t er minals 3 & 5), MBC , and F/S . W hen chec king 5VDC contr ol v oltage , al w a y s place the r ed positiv e test lead from the m ultimet er t o the whit e K5 connector pin closest t o the red K4 connect or . See Fig . 2. Then place[...]

32 c. Mechanical Backup Bin Contr ol (MBC) –K8 connector pins #3 and #4 gr a y (GY) wires: When MBC is closed (calling f or ice), 5VDC is pr esent fr om the whit e K5 connector pin closest t o red K4 connect or t o the K8 connect or pin #3 and #4 gr a y (GY) wires . Diagnosis: If 5VDC is not present t o either pin, CB is bad and must be replaced.[...]

33 D . Bin Contr ol Check 1 . Infr ar ed Sensor Chec k IMPOR T ANT Makesur eS1dipswitch7isinthe"ON"position.  Thisallowsthecontr olboard to monit or the infrared sensor along with the mechanical bac kup bin control. 1) Remo ve the fr ont panel. 2)Mov ethepowers witchtothe?[...]

34 Infrar ed Sensor Infrar ed Sensor Housing Lens Infrar ed Sensor LED Infrar ed Sensor LED F ig. 3 Thumbscre w F ig. 4 Chute Assemb ly Actuat or Paddle Spout Strap P ro ximit y S witch Strap 2. Mechanical Backup Bin Contr ol Check When the actuat or paddle is not engaged MBC is closed and the icemak er pr oduces ice. a) Mechanical Bac kup Bin Cont[...]

35 6)Makesur ethe"GM"LEDison.  Thereisadela yofatleast30secondsbef orethe"GM" LEDtur nsonaf terpo wer -up .  Aft erthe"GM"LEDtur nson,pressthe"SER VICE"but ton located on CB t o bypass the 5-minut e ice pu[...]

36 E. Float S witch Chec k and Cleaning 1 . Float S witch Check 1)Remo vethefr ontpanel,thenmo v ethepow ers witchtothe"OFF"position.  2)Mov ethecontrols witchtothe"DRAIN"position. 3)Mov ethepowers witchtothe"ON"position.  4)?[...]

37 Reservoir Reservoir C ov er Float Switch Assemb l y Red (R) (upper oats witch) Black (BK) (common) Dark Blue (DBU) (lower oatswitch) Upper Float (blue) Magnet (to war ds top) Magnet (to war ds top) Low er Float (white) Plastic Ret ainer Clip Spring Retainer Clip F ig. 5 F ig. 6 3) Wipedo wnF/Sassemb lywitha[...]

38 F . Diagnostic Charts Bef or e consulting the diagnostic char ts, chec k for corr ect installation, proper v oltage per unit nameplate ,andadequatewat ersupply . CheckCBusingthestepsin"IV .C . Contr olBoar d Check."Chec kthattheS1dipswitchset tingsareinthef act [...]

39 No Ice Pr oduction - Possib le Cause Ice Pur ge Cyc le Continued 3. Gear Motor P rot ect R ela y a) Open windings . b) Contacts stuc k open. F reeze Cyc le 1. Gear Motor P rotect R elay a) Open. 2. Control Boar d a) No power t o pump-down solenoid v alve . b) X1 rela y defectiv e. 3. P ump-Down Solenoid V alv e a) Open coil. b) Sticking . 4. Mag[...]

40 No Ice Pr oduction - Possib le Cause 4. Control Boar d a) Nopowert o oats witchornotr eading oats witchcondition. b) No power t o inlet water v alve . Shutdown 1. Infrar ed Sensor Bin Contr ol a) Dirt y lens. b) Def ectiv e. c) Contr ol boar d (no pow er to IS). 2. Mechanical Backup Bin Contr ol a) T ripped wi[...]

41 V . R emo v al and R eplacement of Components W ARNING 1 . This unit should be diagnosed and repair ed only b y quali ed ser vice personnel t o reduce the risk of death, electr ic shoc k, serious injur y , or re . 2. Mov ethepow ers witchtothe"OFF"positionandunplugtheicemak erfr om the el[...]

42 1 . R efr igerant R ecovery The icemaker unit is pr ovided with r efrigerant ser vice v al v es . Using proper r efrigerant practices , r ecov er the refrigerant fr om the ser vice v alv es and st or e it in an appr ov ed container . Do not discharge the r efrigerant int o the atmospher e. 2. Brazing W ARNING 1 . R-404Aitselfisnot[...]

43 4) Close the low -side val v e and high-side val v e on the g auge manif old. 5) Disconnect the gauge manif old hose from the v acuum pump and at tach it t o a refrigerant service cylinder . Remember t o loosen the connection and purge the air fr om the hose. See the rating label inside the icemak er f or the requir ed r efrigerant charge . Hosh[...]

44 Ev apor at or A ssemb ly Ev aporat or Heater Cut ter Cut ter He x Head Bolt Extruding Head A uger O Ring Seal Bolts and Washer s Sock et Head Cap Scre w and Split Lock W asher Gear Motor Gear Motor Barrier Low er Housing O Ring Mechanical Seal Spline Coupling He x Bolt and Washer Sock et Head Cap Scre w and Split Lock W asher W asher Sock et Hea[...]

45 1 . Upper Bear ing W ear Check T o ensure that the bearing inside the extruding head does not e x ceed the wear t olerance of.02",f ollo wtheinstructionsbelow . 1)Remo vethefr ontpanel. Mov ethepo wers witchtothe"OFF"position,thenunplugthe unit from the electrical outl[...]

46 8)Plugtheunitintotheelectricaloutlet,thenmov ethepowers witchtothe"ON"position to st ar t the aut omatic icemaking process . 9) Replace the fr ont panel in its correct position. 3. Remo v al and R eplacement of Extruding Head 1)Remo vethefr ontpanel,thenmo v ethe?[...]

47 1 3)Mov ethecontr ols witchtothe"ICE"position. 1 4)Plugtheunitintotheelectricaloutlet,thenmov ethepowers witchtothe"ON"position to st ar t the aut omatic icemaking process . 1 5) Replace the fr ont panel in its corr ect position. 5. Remo v al and R epl[...]

48 1 7) Remo v e the drier , then place the new drier in position. 1 8)Brazeall t tingswhilepurgingwithnitr ogeng as owingatapressur eof3to4PSIG.  1 9) Use an electronic leak det ect or or soap b ubb les to chec k f or leaks. Add a tr ace of refrigerant t o the sy st em (if using an electr[...]

49 1 2) Remo v e the O-ring and mechanical seal from the housing . If only r eplacing the mechanical seal, proceed t o step 1 5. W ARNING T o help pre vent w at er leaks, be car eful not to damage the surf aces of the O-ring or mechanical seal. 6b. Low er Housing 1 3) Remo v e the he x bolts w/washers securing the low er housing t o the gear mot or[...]

50 1 1) Remov e the gear motor brac ket and spline coupling fr om the old gear mot or and place on the new gear mot or . 1 2) Install the new gear mot or and reconnect the electrical wires . 1 3) Replace the r emo v ed par ts in the re ver se order of which the y wer e remov ed. 1 4) Replace the t op and side panels in their corr ect positions. 1 5[...]

51 VI. Cleaning and Maintenance This icemaker m ust be cleaned and maintained in accor dance with the instr uction manual and labels pr o vided with the icemak er . Consult with your local distrib ut or about cleaning and maintenance service. T o obtain the name and phone number of your local distrib ut or , visit www .hoshizaki.com or call Hoshiza[...]

52 7) P our the cleaning solution ov er the extruding head until the e v aporator assemb ly and thereservoirar efullandthesolutionstar tstoov er owint othedrainpan. Note: If there is e x cess scale on the e xtr uding head, ll the e v aporat or assemb l y and reservoir as described abov e, then use a clam[...]

53 1 1) W ipe down the infrar ed sensor lens, (located on the bot t om of the icemak er) with the cleaning solution. Next, rinse the cleaning solution of f of the infrared sensor lens with a clean, damp cloth. Infrar ed Sensor Infrar ed Sensor Housing Lens 1 2)Replacethet oppanelinitscorr ectposition. Mov ethecontr [...]

54 3) P our the sanitizing solution ov er the extruding head until the e v aporator assemb ly and thereservoirar efullandthesolutionstar tstoov er owint othedrainpan. 4) Remo ve the pr o ximit y s witch fr om the chut e assemb l y , then remo v e the chute assemb ly from the icemak er . 5) Remo ve the pac k[...]

55 4) P our the sanitizing solution ov er the extruding head until the e v aporator assemb ly and thereservoirar efullandthesolutionstar tstoov er owint othedrainpan. 5) Replace the spout and str ap in their corr ect positions . 6) Allow the icemak er to sit f or about 1 0 minutes bef ore oper ation. 7)R[...]

56 Maintenance Sc hedule F requency Ar ea T ask Monthly Ext er nal W at er F ilter s Check f or proper pr essure and change if necessary . Icemaker and Dispenser Unit/ Stor age Bin Exterior Wipe do wn with clean, sof t cloth. Use a damp cloth containing a neutral cleaner to wipe of f oil or dir t build up . Clean any chlorine staining (rust colored[...]

57 C. Pr eparing the Icemak er f or Long Stor age C A UTION When st or ing the icemak er f or an ext ended time or in sub-freezing temper atur es , f ollow the instructions below to pr ev ent damage. When the icemak er is not used for t wo or thr ee day s under nor mal conditions, it is suf ficientt oonl ymov ethepowers witchto[...]