Hoshizaki F-450MAH-C manual

Hoshizaki “A Superior Degree of Reliability” www .hoshizaki.com Models F-450MAH(-C) Modular Flaker Hoshizaki America, Inc. Number: 73112 Issued: 8-21-2009 SER V I CE MA NU A L ®[...]

2 IMPOR T ANT 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 w[...]

3 CONTENTS I. Specifications .............................................................................................................. ...... 4 1. F-450MAH .................................................................................................................... 4 2. F-450MAH- C .......................................................[...]

4 AC SUPPLY VOLTAGE 115/60/1 COMPRESSOR 120 V 8.5 RLA 51 LRA GEAR MOTOR 120 V 1.6 FLA 1/6 HP FAN MOTOR 115 V 0.85FLA 50W OTHER 120 V 0.03A MAXIMUM FUSE SIZE 20 A MAX. HACR BREAKER (USA ONLY) 20 A MAX. CIRC. BREAKER (CANADA ONLY) 20 A MINIMUM CIRCUIT AMPACITY 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lb[...]

5 AC SUPPLY VOLTAGE 115/60/1 COMPRESSOR 120 V 8.5 RLA 51 LRA GEAR MOTOR 120 V 1.6 FLA 1/6 HP FAN MOTOR 115 V 0.85FLA 50W OTHER 120 V 0.03A MAXIMUM FUSE SIZE 20 A MAX. HACR BREAKER (USA ONLY) 20 A MAX. CIRC. BREAKER (CANADA ONLY) 20 A MINIMUM CIRCUIT AMPACITY 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lb[...]

6 II. General Information 1. Construction Water Supply Inlet Junction Box Condenser Fan Motor Compressor Drier Control Water Valve Bin Control Ice Chute Evaporator Flush Water Valve Control Box Gear Motor[...]

7 2. Control Bo x Lay out Note: The above component names are identical with the wiring label, but not with the parts list.[...]

8 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 CA UTION 1. Fragile, handle ve[...]

9 Fig. 1 [c] Sequence Fig. 2[...]

10 Fig. 3 E D O C T R A P1 0 - 5 0 3 7 3 4 L E D O M1 0 C 4 4 1 A A 2 H G N I T A Rz H 0 6 / 0 5 C A V 4 2 1 T. c e s 5 1 ± 0 6 2 T. c e s 2 2 ± 0 9 3 T. c e s 5 4 ± 0 5 1 4 Ts s e l r o . c e s 1 5 T% 0 7 ± . c e s 7 . 6 6 T% 0 7 ± . c e s 7 . 6[...]

11 Functions of Terminals 1) Terminals 1, 2 Power supply AC 24V. 2) Terminals 3, 4 Control X 1 (GM) and X 2 (CM) Relays. When closed, energize X 1 (GM) in 1 sec. and X 2 (CM) in 60 sec. When opened, de-energize X 1 (GM) in 150 sec. and X 2 (CM) in 90 sec. 3) Terminals 5, 6 Control X 1 (GM) and X 2 (CM) Relays. When opened, de-energize X 1 (GM) and [...]

12 III. T echnical Inf ormation 1. W ater Cir cuit and Refrigeration Circuit[...]

13 2. Wiring Dia gram [a] F-450MAH[...]

14 [b] F-450MAH-C[...]

15 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.[...]

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

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

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

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

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

21 [g] When flush timer operates (for 21 min. every 12 hours), flush water valve opens and flushes reservoir and evaporator.[...]

22 [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 contact of circuit protect relay does not move even when the coil is energized.[...]

23 [i] When pressure switch opens, power supply to the control board is cut off causing the compressor and gear motor to turn off immediately.[...]

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

25 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 W A 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. [...]

26 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 W A 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 [...]

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 W A 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 [...]

28 APPROXIMATE Ambient ICE PRODUCTION Temp. (°F) PER 24 HR. 70 484 220 462 209 442 201 80 424 192 406 184 389 176 90 372 169 362 164 341 155 lbs./day kg/day 100 327 148 313 142 294 133 APPROXIMATE ELECTRIC 70 879 -- 885 -- 890 -- CONSUMPTION 80 896 -- 901 -- 907 -- 90 912 -- 918 -- 928 -- watts 100 937 -- 947 -- 956 -- APPROXIMATE WATER 70 0 0 58 [...]

29 APPROXIMATE Ambient ICE PRODUCTION Temp. (°F) PER 24 HR. 70 430 195 410 185 395 180 80 380 170 365 165 350 160 90 135 150 325 150 310 140 lbs./day kg/day 100 300 135 290 130 270 120 APPROXIMATE ELECTRIC 70 883 -- 891 -- 898 -- CONSUMPTION 80 906 -- 913 -- 921 -- 90 928 -- 936 -- 944 -- watts 100 953 -- 961 -- 964 -- APPROXIMATE WATER 70 52 195 [...]

30 IV . 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 continuity and replace. 4. Blown fuse. 4. Replace. b) Power Switch (Control Box) 1. Off position. 1. Move to ON position[...]

31 PROBLEM POSSIBLE CAUSE REMEDY c) Gear Motor Relay 1. Coil winding opened. 1. Replace. 2. Bad contacts. 2. Check for continuity and replace. d) Control Timer (Printed Circuit Board) 1. Broken. 1. Replace. e) Gear Motor Protect Relay 1. Coil winding opened. 1. Replace. 2. Bad contacts. 2. Check for continuity and replace. [4] Water has been suppli[...]

32 PROBLEM POSSIBLE CAUSE REMEDY [7] Gear Motor and Compressor start but no ice is produced. a) Refrigerant Line 1. Gas leaks. 1. 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 clogged. 2. Replace the clogged component. b) S[...]

33 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 temperature t[...]

34 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[...]

35 IMPORT ANT 1. 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. 2. Always install a new filter drier every time the sealed refrigeration system is opened. 3. Do not leave the system open for longer than 15 minutes[...]

36 2. Brazing W ARNING 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 . Al[...]

37 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 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[...]

38 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) Plu[...]

39 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 [...]

40 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 cy[...]

41 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 [...]

42 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 i[...]

43 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. Remov al and Repla[...]

44 14) Move the flush switch to the “ICE” position. 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 IMPORT ANT Ensure all components, fasteners and[...]

45 2. Cleaning and Sanitizing Instructions W ARNING 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 c[...]

46 [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[...]

47 [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[...]

48 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[...]

49 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[...]

50 3. Maintenance Instructions 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 periodic inspection, maintenance and replacement: Extruding Head Housing Gear Motor Auger Mec[...]

51 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 [...]