73113 NO: ISSUED: REVISED: HOSHIZAKI June 7, 2004 June 15, 2005 MODULAR FLAKER MODEL F-801MAH/-C F-801MWH/-C SERVICE MANUAL
IMPORTANT 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.
Please review this manual. It should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified service technicians should service and maintain the icemaker. This manual should be made available to the technician prior to service or maintenance. CONTENTS I. Specification ...................................................................................................................... 5 1. Icemaker ...........................................................
5. Removal and Replacement of Expansion Valve ......................................................... 43 6. Removal and Replacement of Water Regulating Valve (water-cooled model only) .... 44 7. Removal and Replacement of Evaporator Assembly ................................................. 45 8. Removal and Replacement of Fan Motor ................................................................... 49 9. Removal and Replacement of Control Water Valve ....................................................
I. Specification 1. Icemaker F-801MAH AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR OTHER MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER gal./24HR (gal./100 lbs.
F-801MWH AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR OTHER MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER WATER-COOLED CONDENSER gal./24HR (gal./100 lbs.
F-801MAH-C AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR OTHER MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER gal./24HR (gal./100 lbs.
F-801MWH-C AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR OTHER MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER WATER-COOLED CONDENSER gal./24HR (gal./100 lbs.
II. General Information 1.
F-801MWH/-C Control Water Valve Water Supply Inlet Bin Control Junction Box Ice Chute Evaporator Water Regulator Expansion Valve Compressor Flush Water Valve Drier Control Box Gear Motor 10
2. Control Box Layout F-801MAH/-C FLUSH TIMER WATER CONTROL RELAY TRANSFORMER GEAR MOTOR RELAY CONNECTOR FLUSH CIRCUIT PROTECT RELAY FAN MOTOR CAP PRESSURE SWITCH GEAR MOTOR PROTECT RELAY GEAR MOTOR CAP. FLUSH SWITCH ICE POWER SWITCH STARTER FUSE START CAPACITOR FUSE (GEAR MOTOR) RUN CAPACITOR CONTROL TIMER Note: The above component names are identical with the wiring label, but not with the parts list.
F-801MWH/-C FLUSH TIMER WATER CONTROL RELAY TRANSFORMER GEAR MOTOR RELAY CONNECTOR CIRCUIT PROTECT RELAY PRESSURE SWITCH FLUSH GEAR MOTOR CAP.
III. Technical Information 1.
F-801MWH/-C 14
2.
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.
[b] When reservoir has been filled, gear motor starts immediately.
[c] Compressor starts about 60 sec. after gear motor starts.
[d] Bin control operates, and about 6 sec. later, compressor and gear motor stop simultaneously.
[e] Low water (except water-cooled model).
[f] Low water (water-cooled model), or dirty air filter (air-cooled model), pressure switch to “OPEN”, compressor and gear motor operate intermittently.
[g] When flush switch is moved to “FLUSH” position, flush water valve opens and flushes reservoir and evaporator.
[h] When flush timer operates (for 15 min. every 12 hours).
[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.
[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.
4. Timing Chart Miswiring. Circuit Protect Relay operates.) Proper wiring. The unit starts. BIN CONTROL OFF 1. CIRCUIT PROTECT RELAY ON ON OFF UPPER 2. WATER LEVEL UPPER 3. FLOAT SWITCH LOWER 4. WATER CONTROL RELAY 5. CONTROL WATER VALVE 6. FLUSH TIMER 7. FLUSH SWITCH 8. FLUSH WATER VALVE 9. BIN CONTROL LOWER BOTTOM ON OFF ON OFF ON OFF ON OFF 1-2 2-3 FLUSH ICE ON OFF ON OFF 1 sec 10. GEAR MOTOR RELAY 11. GEAR MOTOR 12. FAN MOTOR 6 sec OFF ON OFF ON OFF 60 sec 13.
FLUSH TIMER LOW WATER 1. CIRCUIT PROTECT RELAY ON OFF UPPER 2. WATER LEVEL UPPER 3. FLOAT SWITCH LOWER 4. WATER CONTROL RELAY 5. CONTROL WATER VALVE 6. FLUSH TIMER LOWER BOTTOM ON OFF ON OFF ON OFF ON OFF 1-2 2-3 21 min every 12 hr FLUSH 7. FLUSH SWITCH 8. FLUSH WATER VALVE 9. BIN CONTROL ICE ON OFF ON OFF 150 sec 10. GEAR MOTOR RELAY 11. GEAR MOTOR 12. FAN MOTOR 1 sec 1 sec OFF ON OFF ON OFF 90 sec 13. COMPRESSOR 150 sec ON 60 sec ON OFF 14.
FLUSH SWITCH FLUSH 1. CIRCUIT PROTECT RELAY PRESSURE SWITCH ICE OFF ON ON OFF UPPER 2. WATER LEVEL UPPER 3. FLOAT SWITCH LOWER 4. WATER CONTROL RELAY 5. CONTROL WATER VALVE 6. FLUSH TIMER LOWER BOTTOM ON OFF ON OFF ON OFF ON OFF 1-2 2-3 FLUSH 7. FLUSH SWITCH 8. FLUSH WATER VALVE 9. BIN CONTROL ICE ON OFF ON OFF 150 sec 10. GEAR MOTOR RELAY 11. GEAR MOTOR 12. FAN MOTOR 1 sec OFF ON OFF ON OFF 90 sec 13. COMPRESSOR 1 sec ON 60 sec 60 sec ON OFF 14.
5. Performance Data F-801MAH APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. (TOTAL) gal. / day (l/day) EVAPORATOR OUTLET TEMP. °F (°C) HEAD PRESSURE PSIG (kg/cm2G) SUCTION PRESSURE PSIG (kg/cm2G) TOTAL HEAT OF REJECTION Ambient Temp. (F) 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 Water Temp.
F-801MWH APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. (TOTAL) gal. / day (l/day) EVAPORATOR OUTLET TEMP. °F (°C) HEAD PRESSURE PSIG (kg/cm2G) SUCTION PRESSURE PSIG (kg/cm2G) Ambient Temp. (F) 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 WATER FLOW FOR CONDENSER PRESSURE DROP OF COOLING WATER LINE HEAT OF REJECTION FROM CONDENSER HEAT OF REJECTION FROM COMPRESSOR Water Temp.
F-801MAH-C APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg/day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. (TOTAL) gal. / day (l/day) EVAPORATOR OUTLET TEMP. °F (°C) HEAD PRESSURE PSIG (kg/cm2G) SUCTION PRESSURE PSIG (kg/cm2G) TOTAL HEAT OF REJECTION Ambient Temp. (F) 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 Water Temp.
F-801MWH-C APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. (TOTAL) gal. / day (l/day) EVAPORATOR OUTLET TEMP. °F (°C) HEAD PRESSURE PSIG (kg/cm2G) SUCTION PRESSURE PSIG (kg/cm2G) Ambient Temp. (F) 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 70 80 90 100 WATER FLOW FOR CONDENSER PRESSURE DROP OF COOLING WATER LINE HEAT OF REJECTION FROM CONDENSER HEAT OF REJECTION FROM COMPRESSOR Water Temp.
IV. Adjustment of Components 1. Adjustment of Water Regulating Valve (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 line of the system. Or prepare a thermometer to check the condenser drain temperature.
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. FINE 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 position. COARSE 3) Place the cutter head so that the pin on the top of the auger fits into the selected hole. 4) Secure the cutter head by the bolt.
V. Service Diagnosis 1. No Ice Production PROBLEM [1] [2] The icemaker will not start. Water flow does not stop, and the icemaker will not start POSSIBLE CAUSE a) Power Supply OFF position. Loose connection. Bad contacts. 1. 2. 3. b) Power Switch (Control Box) 4. 1. 2. c) Fuse (Control Box) 1. Blown out. 1. d) Circuit Protect Relay 1. Miswiring. 1. e) Flush Timer 1. 2. Flushing out. Bad contacts. 1. 2. f) Flush Switch 1. 2. FLUSH position. Bad contacts. 1. 2.
PROBLEM [4] Water has been supplied, Fan Motor starts, but Gear Motor and Compressor will not start. [5] Gear Motor and Compressor start but operate intermittently. POSSIBLE CAUSE 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. a) Pressure Switch 1. Dirty Air Filter or Condenser. Ambient or condenser water temperature too warm. Condenser water pressure too low or off.
2. Low Ice Production PROBLEM [1] Low ice production POSSIBLE CAUSE a) Refrigerant Line 1. Gas leaks. 2. Refrigerant line clogged. 3. Overcharged. b) High-side Pressure Too High c) Expansion Valve (not adjustable) 1. Dirty Air Filter or Condenser. 2. Ambient or condenser water temperature too warm. 3. Condenser water pressure too low or off. [Water-cooled model only] 4. Fan rotating too slow. 5. Water Regulating Valve clogged. [Water-cooled model only] 6. Condensing unit out of order. 1.
3. Other PROBLEM [1] Abnormal noise POSSIBLE CAUSE a) Fan Motor b) Compressor c) Refrigerant Lines d) Gear Motor (Ice Making) e) Evaporator [2] Overflow from Reservoir (Water does not stop.) a) Water Supply b) Control Water Valve c) Float Switch [3] Gear Motor Fuse blown frequently. 1. Bearing worn out. 2. Fan blade deformed. 3. Fan blade does not move freely. 1. Bearings worn out, or cylinder valve broken. 2. Mounting pad out of position. 1. Rub or touch lines or other surfaces. 1.
VI. Removal and Replacement of Components IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORTANT 1. The Polyolester (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.
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 highside 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 reclaimed refrigerant which meets ARI Standard No. 700-88 be used. 6) A liquid charge is recommended for charging an R-404A system. Invert the service cylinder.
3. Removal and Replacement of Compressor IMPORTANT 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 compressor wiring. 3) Recover the refrigerant and store it in an approved container, if required by an applicable law.
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 aircooled 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 the panels in their correct position, and turn on the power supply. 4.
5. Removal and Replacement of Expansion Valve IMPORTANT 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 off the power supply, and remove the panels. 2) Recover the refrigerant and store it in an approved container, if required by an applicable law.
6. Removal and Replacement of Water Regulating Valve (water-cooled model only) IMPORTANT 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-off valve. 2) Recover the refrigerant and store it in an approved container. 3) Disconnect the capillary tube using brazing equipment.
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 three thumbscrews and take off the spout from the evaporator. Cutter 8) Remove the bolt and lift off the cutter.
13) Recover the refrigerant and store it in an approved container, if required by an applicable law. IMPORTANT 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 brazing-connections of the expansion valve and the copper tube -low side from the evaporator, using brazing equipment.
26) Assemble the removed parts in the reverse order of the above procedure. WARNING 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 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.
Rubber O-ring Nylon Ring Bolt Washer Auger Cutter Extruding Head Washer Mechanical Seal Socket Head Cap Screw O-ring Bearing - Lower Evaporator Washer Bolt Socket Head Cap Screw Washer Coupling - Spline Barrier Gear Motor 48
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 power supply. 9. Removal and Replacement of Control Water Valve 1) Turn off the power supply, remove the panels and close the water supply line shut-off valve.
10. Removal and Replacement of Flush Water Valve 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 from the flush water valve. 4) Remove the flush water valve from the bracket. 5) Remove the drain pipe from the flush water valve.
VII. Cleaning and Maintenance IMPORTANT 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 WARNING When shutting off the icemaker for an extended time, drain out all water from the water line and remove the ice from the storage bin. The storage bin should be cleaned and dried.
[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 and Remote Air-Cooled Models]. 2. Cleaning and Sanitizing Instructions WARNING 1. HOSHIZAKI recommends cleaning this unit at least once a year.
[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 out all water from the water line. 6) Turn off the power supply. 7) Remove the strap connecting the spout to the chute assembly.
[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. IMPORTANT For safety and maximum effectiveness, use the solution immediately after dilution. [d] Sanitizing Procedure - Initial The sanitizing process will sanitize the icemaker. 1) Close the water supply line shut-off valve. 2) Remove the strap connecting the spout to the chute assembly.
14) Replace all parts in their correct positions. IMPORTANT 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 panel and front panel in their correct positions. Make ice using the solution until the icemaker stops making ice.
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 bin liner with the solution. 21) Flush out any solution from the storage bin. 22) Turn on the power supply and start the automatic icemaking process. IMPORTANT 1.
3. Maintenance IMPORTANT 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 Seal These parts should be inspected at least once a year or every 10,000 hours of operation. Their service life, however, depends on water quality and environment.
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 (except water-cooled model) Check the condenser once a year, and clean if required by using a brush or vacuum cleaner.
