Instruction Manual Modular Flaker Models F-450MAJ(-C) F-801MAJ(-C), MWJ(-C) F-1002MAJ(-C), MWJ(-C), MRJ(-C), MLJ F-1501MAJ(-C), MWJ(-C), MRJ(-C) FD-650MAH-C, MWH-C, MRH-C FD-1002MAJ-C, MRJ-C hoshizakiamerica.
WARNING Only qualified service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit www.hoshizaki.com. No installation or service should be undertaken until the technician has thoroughly read this Instruction Manual. Likewise, the owner/manager should not proceed to operate the appliance until the installer has instructed them on its proper operation.
IMPORTANT This manual should be read carefully before the appliance is installed and operated. Read the warnings and guidelines contained in this manual carefully as they provide essential information for the continued safe use and maintenance of the appliance. Retain this manual for any further reference that may be necessary. CONTENTS Important Safety Information.................................................................................................. 5 I. Specifications..........................
K. Bin Control Check........................................................................................................ 38 1. Infrared Sensor Check............................................................................................ 38 2. Infrared Sensor Shutdown Delay............................................................................ 40 L. Alarm Safeties.............................................................................................................. 41 III. Maintenance....
Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury. NOTICE Indicates a situation which could result in damage to the appliance or property. IMPORTANT Indicates important information about the installation, use, and care of the appliance.
WARNING, continued • The appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. • Children should be properly supervised around the appliance. • Do not climb, stand, or hang on the appliance or allow children or animals to do so.
I. Specifications A. Electrical and Refrigerant Data The rating label and nameplate provide electrical and refrigerant data. The rating label can be seen by removing the front panel. The nameplate is located on the rear panel. For certification marks, see the nameplate. We reserve the right to make changes in specifications and design without prior notice. 1. F-450MAJ(-C) Single Phase Model Number F-450MAJ(-C) AC Supply Voltage 115/60/1 Compressor 115V 8.4RLA 50LRA Gear Motor 115V 2.
3. F-1002M_J(-C) Single Phase F-1002MAJ(-C) F-1002MWJ(-C) 115/60/1 115/60/1 115V 11.2RLA 115V 10.7RLA 93LRA 93LRA Gear Motor 115V 3.0FLA 200W 115V 3.0FLA 200W Fan Motor 115V 1.0FLA ––– 1/15HP Other 115V 0.03A 115V 0.03A Maximum Fuse Size 20 AMPS 20 AMPS Max. HACR Breaker 20 AMPS 20 AMPS (USA Only) Max. Circuit Breaker 20 AMPS 20 AMPS (Canada Only) Minimum Circuit 20 AMPS 20 AMPS Ampacity Design Pressure HI-467PSI HI-427PSI LO-250PSI LO-250PSI Refrigerant 404A 2 LB. 4 OZ. 404A 12.3 OZ.
5. FD-650M_H-C Model Number AC Supply Voltage Compressor Gear Motor Fan Motor Other Maximum Fuse Size Max. HACR Breaker (USA Only) Max. Circuit Breaker (Canada Only) Minimum Circuit Ampacity Design Pressure Refrigerant FD-650MAH-C 115/60/1 115V 7.9RLA 54.5LRA 120V 2.3FLA 1/4HP 115V 1.0FLA 1/15HP 115V 0.03A 20 AMPS 20 AMPS Single Phase FD-650MWH-C 115/60/1 115V 5.5RLA 50LRA 120V 2.3FLA 1/4HP 115V 0.03A 20 AMPS 20 AMPS FD-650MRH-C 115/60/1 115V 5.5RLA 50LRA 120V 2.
B. Dimensions/Connections 1. Air-Cooled Models (MAJ(-C)) Units: mm [in.
2. Water-Cooled Models (MWJ(-C)) Units: mm [in.
3. Remote Models (MRJ(-C)) Units: mm [in.
4. Low Side, Parallel Rack System Models (MLJ(-C)) Units: mm [in.] A B C D E F G H Side F-1002MLJ 560 [22] 555 [21-7/8] 395 [15-9/16] 658 [25-7/8] 598 [23-1/2] 575 [22-5/8] 169 [6-5/8] 24 [1] Rear 32 [1-1/4] G I 35 [1-3/8] J 64 [2-1/2] K 434 [17-1/16] L 40 [1-9/16] Bottom M 100 [3-15/16] NOTICE • Allow 6" (15 cm) clearance at rear and sides for proper air circulation and ease of maintenance and/or service should they be required. Allow 24" (61 cm) clearance at top to allow for removal of the auger.
5. Remote Condenser Unit URC-5F (use with F-1002MRJ(-C), FD-650MRH-C, FD-1002MRJ-C) Units: mm [in.] NOTICE Allow 24" (61 cm) clearance at front and rear for proper air circulation and ease of maintenance and/or service should they be required. Icemaker Model F-1002MRJ F-1002MRJ-C FD-650MRH-C FD-1002MRJ-C URC-5F Heat of Rejection AT 90°F (32°C) WT 70°F (21°C) 7,660 BTU/hr 7,840 BTU/hr 4,900 BTU/hr 8,900 BTU/hr Top Rear 6. Remote Condenser Unit URC-14F Units: mm [in.
7. Remote Condenser Unit URC-23F (use with F-2001MRJ(3)(-C)) Units: mm [in.] NOTICE Allow 24" (61 cm) clearance at front and rear for proper air circulation and ease of maintenance and/or service should they be required.
II. Installation and Operating Instructions WARNING • The appliance must be installed in accordance with applicable national, state, and local codes and regulations. • Failure to install, operate, and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after installation.
• Remove the protective plastic film from the panels. If the appliance is exposed to the sun or to heat, remove the film after the appliance cools. • Check that the refrigerant lines do not rub or touch lines or other surfaces, and that the fan blade (if applicable) turns freely. • Check that the compressor is snug on all mounting pads. • Flaker models can be installed on an ice storage bin only. Cubelet models can be installed on either a dispenser unit or an ice storage bin.
D. Dispenser Unit/Ice Storage Bin and Icemaker Setup WARNING The installer must ensure the dispenser unit/ice storage bin is compatible with the icemaker, and the dispenser unit/ice storage bin and icemaker are properly attached and secured. 1a) Dispenser Unit: Follow the dispenser unit's setup procedure. Note that only cubelet models can be installed on a dispenser unit; flaker models cannot be installed on a dispenser unit.
E. Electrical Connection WARNING For All Models • Electrical connection must be hard-wired and must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, fire, or damage. • The icemaker requires an independent power supply of proper capacity. See the nameplate for electrical specifications.
F-450MAJ(-C) F-801M_J(-C) F-1002M_J(-C) FD-1002MAH-C FD-1002MRJ-C FD-650M_H-C WARNING ELECTRICAL CONNECTION THIS UNIT MUST BE GROUNDED Failure to properly ground or wire this unit could result in death, serious injury, or severe damage to the icemaker. The white lead must be connected to the neutral conductor of the power source. See diagram below. 115-120/60/1 JUNCTION BOX 115-120V L N BROWN WHITE Based on 435005 Fig. 3b Fig.
F. Water Supply and Drain Connections See Fig. 4, 5, and 6 WARNING Water supply and drain connections must be installed in accordance with applicable national, state, and local regulations. NOTICE • Normal operating water temperature must be within 45°F to 90°F (7°C to 32°C). Operation of the appliance, for extended periods, outside of this normal temperature range may affect appliance performance. • Water supply pressure must be a minimum of 10 PSIG and a maximum of 113 PSIG.
1. Icemaker Icemaker Water Supply Inlet 1/2" Female Pipe Thread (FPT) Minimum Icemaker Water Supply Line Size 1/4" Nominal ID Copper Water Tubing or Equivalent Icemaker Drain Outlet 3/4" Female Pipe Thread (FPT) Minimum Icemaker Drain Line Size 3/4" Nominal ID Hard Pipe or Equivalent • An icemaker water supply line shut-off valve and drain valve must be installed. • Be sure there is sufficient extra water supply line and drain line for the appliance to be pulled out for service.
2. Water-Cooled Condenser a) Connection to an Open Drain System Condenser Water Supply Inlet 1/2" Female Pipe Thread (FPT) Minimum Condenser Water Supply Line Size 1/4" Nominal ID Copper Water Tubing or Equivalent Condenser Drain Outlet 3/8" Female Pipe Thread (FPT) Minimum Condenser Drain Line Size 1/4" Nominal ID Hard Pipe or Equivalent • A condenser water supply line shut-off valve and drain valve must be installed. • In some areas, a back flow preventer may be required in the cooling water circuit.
b) Connection to a Closed Loop System Condenser Water Supply Inlet 1/2" Female Pipe Thread (FPT) Minimum Condenser Water Supply Line Size 1/4" Nominal ID Copper Water Tubing or Equivalent Condenser Return Outlet 3/8" Female Pipe Thread (FPT) Minimum Condenser Return Line Size 1/4" Nominal ID Copper Water Tubing or Equivalent • Shut-off valves and drain valves must be installed at both the condenser water supply inlet and condenser return outlet. • Minimum water flow to the condenser is 4 GPM.
G. Remote Condenser Unit Installation WARNING • Installation of remote condenser unit must be performed by properly trained and EPA-certified service personnel. • The remote condenser unit must be installed in accordance with applicable national, state, and local codes and regulations. • Failure to install the remote condenser unit within these guidelines may adversely affect safety, performance, component life, and warranty coverage.
2. Checks Before Installation 1) Remove the shipping carton, tape, and packing material. 2) Check that the refrigerant lines do not rub or touch lines or other surfaces, and that the fan blades move freely. 3. Setup 1) Assemble 2 sets of legs using the legs, bolts, and nuts provided. See Fig. 9. 2) Position 1 of the plates provided between a set of legs and the remote condenser unit, then secure the legs to the remote condenser unit with the bolts and nuts provided.
4. Line Set Size and Refrigerant Charge NOTICE The icemaker, line set, and remote condenser unit must contain the same type of refrigerant. Mixing of refrigerants will result in improper operation and possible damage to the refrigeration system. Hoshizaki Icemaker F-1002MRJ(-C) FD-650MRH-C FD-1002MRJ-C F-1501MRJ(-C) Line Set Size and Refrigerant Charge Line Set Greater than 66' (20 m) Hoshizaki Line Set Up to 66' (20 m) Maximum 100' (30.
5. Line Set Installation Precharged factory line sets, available as optional equipment from Hoshizaki America, are recommended. For details, see "II.G.5.a) Factory Line Set Installation." Field fabricated line sets are allowed. For details, see "II.G.5.b) Field Fabricated Line Set Installation." a) Factory Line Set Installation 1) Route the factory line set (see "II.G.4 Line Set Size and Refrigerant Charge" for details) from the remote condenser unit to the icemaker.
(1) Factory Line Set Modification 1) Recover the line set charge through the Schrader access ports on the Parker quick connect couplings and store it in an approved container. Do not discharge the refrigerant into the atmosphere. Remove the extra line set length or add extra tubing. When adding extra tubing, insulate the additional copper tubes separately. 2) Use an electronic leak detector or soap bubbles to check for leaks.
7) Connect the refrigerant lines to the appropriate male fittings on the remote condenser unit first and then at the icemaker. Make a proper connection as follows: a. Remove the protective covers from the male fitting and female coupling. b. Apply Polyol Ester (POE) refrigerant oil or Parker Super O Lube to the entire male fitting, including O‑ring, diaphragm, and threads, before making the connection. See Fig. 11. NOTICE! Do not use thread sealant on the fittings.
6. Electrical Connection WARNING • Electrical connection must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, fire, or damage. • To reduce the risk of electric shock, make all remote condenser unit connections before connecting the icemaker power supply. • THE REMOTE CONDENSER UNIT MUST BE GROUNDED.
3) Install a ground wire from the icemaker fan motor junction box to the remote condenser unit junction box. Use wire of an appropriate gage and outdoor rating. 4) Install line and neutral wires from the fan motor leads in the icemaker fan motor junction box to the leads in the remote condenser unit junction box. Use wire of an appropriate gage and outdoor rating. 5) Replace the junction box covers and the louver panel in their correct positions. 7.
H. Parallel Rack System Connection WARNING • Installation must be performed by properly trained and EPA-certified service personnel. • Failure to install the appliance within these guidelines may adversely affect safety, performance, component life, and warranty coverage. • Connect the line set to the rack system per the rack system manufacturer's instructions. NOTICE • The icemaker is shipped with a nitrogen holding charge.
3) Install Parker quick connect couplings on the icemaker end of the line set. OS-QUICK, a universal quick connect coupling kit, is required. NOTICE! Before brazing, remove the Schrader valve core from the access port. When brazing, protect the coupling by using a wet cloth to prevent the coupling from overheating. Do not use silver alloy or copper alloy containing arsenic. Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
Rack System-Braze Connection Braze Connection Fig. 15 Icemaker Male Fitting Female Coupling (Charging Ports) Suction Line (Insulated) See "II.H.1 Line Set Size and Rack System Requirements" for details. Liquid Line (Insulated) See "II.H.1 Line Set Size and Rack System Requirements" for details. Service Loop DO NOT USE THREAD SEALANT Male Fitting Brush Fig. 16 Threads Diaphragm Apply POE Oil or Parker Super O Lube to Entire Male Fitting O-Ring Reference Line Fig.
I. Final Checklist WARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after installation. Make sure that none have fallen into the dispenser unit/ice storage bin.
J. Startup WARNING All parts are factory-adjusted. Improper adjustments may adversely affect safety, performance, component life, and warranty coverage. NOTICE • If the appliance is turned off, wait for at least 3 minutes before restarting the appliance to prevent damage to the compressor. • At startup, confirm that all internal and external connections are free of leaks.
K. Bin Control Check An infrared sensor controls the level of ice in the dispenser unit/ice storage bin. IMPORTANT • Make sure the icemaker has been installed as outlined in this manual and that the water supply is on. • Make sure S1 Dip Switch 7 is in the "ON" position. This allows the control board to monitor the infrared sensor. 1. Infrared Sensor Check 1) Turn off the power supply. 2) Remove the front panel, top panel, and control box cover.
7) "GM" LED and "COMP" LED are on. Use an object to cover the infrared sensor lens at the bottom of the icemaker. If the bottom of the icemaker is not accessible in your application, remove the thumbscrew securing the infrared sensor housing, remove the housing from the base, then cover the infrared sensor lens. See Fig. 19. The yellow LED on the infrared sensor turns on. The yellow LED flashes when ice is at the outer limit of its range and turns steady as ice nears.
2. Infrared Sensor Shutdown Delay This is the delay between the infrared sensor detecting ice and the start of the shutdown sequence. The infrared sensor shutdown delay is factory-adjusted to 100 seconds and no adjustment is required for most dispenser unit/ice storage bin applications. a) Standard Ice Storage Bin: When installed on a standard ice storage bin, any shutdown delay setting is acceptable. b) Dispenser Unit: For typical dispenser unit applications, a 100-second shutdown delay is recommended.
L. Alarm Safeties Should an alarm occur, follow the instructions in the table below to address the alarm. If an alarm continues to occur, contact an authorized service agent. WARNING • Only qualified service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the icemaker power switch or control switch with damp hands. • Before Servicing: Move the icemaker's power switch to the "OFF" position. Turn off the power supply.
III. Maintenance The appliance must be maintained in accordance with the instruction manual and labels provided. Consult with your local Hoshizaki Certified Service Representative about maintenance service. WARNING • Only qualified service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the icemaker power switch or control switch with damp hands. • Before Servicing: Move the icemaker's power switch to the "OFF" position. Turn off the power supply.
A. Maintenance Schedule The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the appliance's environment, and local sanitation regulations. Maintenance Schedule Frequency Area Task Daily Clean the ice scoop using a neutral cleaner. Rinse thoroughly after cleaning. Inspect. Wash with warm water and neutral cleaner if dirty. Check for proper pressure and change if necessary.
B. Cleaning and Sanitizing Instructions The appliance must be cleaned and sanitized at least twice a year. More frequent cleaning and sanitizing may be required in some conditions. WARNING • To prevent injury to individuals and damage to the appliance, do not use ammonia type cleaners. • Carefully follow any instructions provided with the cleaning and sanitizing solutions.
10) In bad or severe water conditions, clean the float switch as described below. Otherwise, continue to step 11. a. Remove the float switch from the reservoir cover. b. Wipe down the float switch with the cleaning solution. c. Rinse the float switch thoroughly with clean water. d. Replace the float switch in its correct position. 11) Wipe down the infrared sensor lens, (located on the bottom of the icemaker) with the cleaning solution.
4) Remove the chute assembly from the icemaker. 5) Remove the chute packing at the bottom of the chute. Remove the 3 ties and the chute insulation. 6) Soak the spout, evaporator packing (F-450), rubber O-ring and nylon ring (FD-650 and larger), spout-to-chute packing, spout-to-chute bracket, and chute in the sanitizing solution for 10 minutes then wipe them down. 7) Rinse the parts thoroughly with clean water. 8) Replace all parts in their correct positions.
13) Turn on the power supply and allow the water system to drain for 5 minutes. 14) Turn off the power supply, then remove the front panel. Move the control switch to the "ICE" position, then replace the front panel in its correct position. 15) Turn on the power supply to start the automatic icemaking process. Allow the icemaker to run for 30 minutes, then turn off the power supply. 16) Pour warm water into the dispenser unit/ice storage bin and melt any remaining ice.
IV. Preparing the Appliance for Periods of Non-Use NOTICE When storing the appliance for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. When the appliance is not used for two or three days under normal conditions, it is sufficient to only move the power switch to the "OFF" position. When storing the appliance for extended time or in sub-freezing temperatures, follow the instructions below. 1.
3. On water-cooled models, remove the water from the water-cooled condenser: 1) Make sure the power supply is off, then remove the front panel and right side panel. 2) Close the condenser water supply line shut-off valve. If connected to a closed loop system, also close the condenser return line shut-off valve. 3) Open the condenser water supply line drain valve. If connected to a closed loop system, also open the condenser return line drain valve.
V. Disposal The appliance contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.
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