FM-600AHE FM-600AWHE FMN-440AHE FMN-440AWHE

FM-600AHE FM-600AWHE FMN-440AHE FMN-440AWHE
NO.
E2AL-662
ISSUED: NOV. 22, 2004
REVISED: OCT. 12, 2007
HOSHIZAKI
MODULAR ICE MAKER
FM-600AHE
FM-600AWHE
FMN-440AHE
FMN-440AWHE
MODEL
SERVICE MANUAL
CONTENTS
PAGE
I. SPECIFICATIONS ------------------------------------------------------------------------------------1. FEATURES ---------------------------------------------------------------------------------------[a] LOW VOLTAGE -----------------------------------------------------------------------------[b] COMPRESSOR STARTUP---------------------------------------------------------------[c] ICE PRODUCTION CONTROL (FAN CONTROL) - FMN-440AHE only --------[d] OVERLOAD PROTECTION --------------------------------------------------------------[e] OVERLOAD ERROR -----------------------------------------------------------------------[f] USER RESET --------------------------------------------------------------------------------[g] ERROR CODES AND RECORDS------------------------------------------------------[h] OTHER INFORMATION --------------------------------------------------------------------[i] CHANGE OF ICE TYPE -------------------------------------------------------------------2. DIMENSIONS/CONNECTIONS --------------------------------------------------------------[a] FM-600AHE, FMN-440AHE --------------------------------------------------------------[b] FM-600AWHE, FMN-440AWHE --------------------------------------------------------3. SPECIFICATIONS ------------------------------------------------------------------------------[a] FM-600AHE ----------------------------------------------------------------------------------[b] FM-600AWHE -------------------------------------------------------------------------------[c] FMN-440AHE --------------------------------------------------------------------------------[d] FMN-440AWHE -----------------------------------------------------------------------------4. CONSTRUCTION ---------------------------------------------------------------------------------
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2
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3
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5
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6
7
8
9
II. MAINTENANCE AND CLEANING INSTRUCTIONS ----------------------------------------- 10
1. EXTRUDING HEAD, HOUSING BEARING, AUGER BEARING ---------------------- 10
2. MECHANICAL SEAL --------------------------------------------------------------------------- 10
3. GEAR MOTOR ----------------------------------------------------------------------------------- 11
4. CONDENSER ------------------------------------------------------------------------------------ 11
5. AIR FILTER (AIR-COOLED MODEL ONLY) ----------------------------------------------- 11
6. WATER VALVE --------------------------------------------------------------------------------- 12
7. CLEANING OF WATER SYSTEM ----------------------------------------------------------- 13
8. PERIODICAL CLEANING --------------------------------------------------------------------- 15
III. TECHNICAL INFORMATION ---------------------------------------------------------------------- 16
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT --------------------------------------- 16
[a] FM-600AHE ---------------------------------------------------------------------------------- 16
[b] FM-600AWHE ------------------------------------------------------------------------------- 17
[c] FMN-440AHE -------------------------------------------------------------------------------- 18
[d] FMN-440AWHE ----------------------------------------------------------------------------- 19
2. WIRING DIAGRAM ------------------------------------------------------------------------------ 20
[a] WIRING DIAGRAM -------------------------------------------------------------------------- 20
[b] CONTROL BOX LAYOUT ----------------------------------------------------------------- 21
3. ICEMAKING MECHANISM -------------------------------------------------------------------- 22
[a] EVAPORATOR (CASING) ---------------------------------------------------------------- 22
[b] AUGER ---------------------------------------------------------------------------------------- 22
[c] EXTRUDING HEAD (BEARING) --------------------------------------------------------- 22
[d] HOUSING ------------------------------------------------------------------------------------- 23
i
[e] MECHANICAL SEAL ---------------------------------------------------------------------- 23
[f] COUPLING (SPLINE JOINT) -------------------------------------------------------------- 23
[g] GEAR MOTOR ------------------------------------------------------------------------------- 23
[h] DEICING HEATER (ALUMINUM CAST HEATER) ---------------------------------- 23
[i] REMOVABLE FLANGE ------------------------------------------------------------------- 23
[j] SOCKET HEAD CAP SCREW ---------------------------------------------------------- 24
4. WATER CIRCUIT -------------------------------------------------------------------------------- 25
[a] RESERVOIR (WATER TANK) ----------------------------------------------------------- 25
[b] FLOAT SWITCH ----------------------------------------------------------------------------- 25
[c] CONTROL WATER VALVE -------------------------------------------------------------- 25
[d] FLUSH WATER VALVE ------------------------------------------------------------------- 25
[e] WATER REGULATOR --------------------------------------------------------------------- 25
[f] DRAINING ICEMAKER IN SUBFREEZING CONDITIONS ------------------------- 25
5. REFRIGERATION CIRCUIT ------------------------------------------------------------------- 28
[a] APPLICABLE PARTS --------------------------------------------------------------------- 28
[b] SERVICE INSTRUCTIONS --------------------------------------------------------------- 28
[c] REFRIGERANT CONTROL (Compressor Cooling) --------------------------------- 28
[d] REFRIGERANT CONTROL (Ice Production Control) ------------------------------- 29
[e] REFRIGERANT CONTROL (Overload Control) -------------------------------------- 29
[f] REFRIGERANT ------------------------------------------------------------------------------ 29
[g] COMPRESSOR ----------------------------------------------------------------------------- 30
[h] EVAPORATOR CASING ------------------------------------------------------------------ 30
[i] CONDENSER -------------------------------------------------------------------------------- 30
[j] CONDENSER COOLING FAN MOTOR------------------------------------------------ 31
[k] WATER REGULATOR --------------------------------------------------------------------- 31
[l] DRIER ------------------------------------------------------------------------------------------ 32
[m] SOLENOID VALVE ------------------------------------------------------------------------ 32
[n] THERMOSTATIC EXPANSION VALVE ----------------------------------------------- 33
[o] ACCESS VALVE --------------------------------------------------------------------------- 33
6. ELECTRIC CIRCUIT ---------------------------------------------------------------------------- 34
[a] BASIC OPERATION ------------------------------------------------------------------------ 34
[b] TIMING CHART ------------------------------------------------------------------------------ 35
[c] SEQUENCE ---------------------------------------------------------------------------------- 36
[d] OPERATION BOARD ---------------------------------------------------------------------- 43
[e] CONTROLLER BOARD ------------------------------------------------------------------- 43
[f] SURGE ABSORBER ----------------------------------------------------------------------- 44
[g] CAPACITOR - XY FILTER ---------------------------------------------------------------- 44
[h] BIN CONTROL SWITCH ------------------------------------------------------------------- 44
[i] CHUTE SWITCH ---------------------------------------------------------------------------- 45
[j] DEICING HEATER (ALUMINUM CAST HEATER) ----------------------------------- 46
[k] CRANKCASE HEATER ------------------------------------------------------------------- 46
[l] SOLENOID VALVE (BYPASS CONTROL) ------------------------------------------- 46
7. OPERATION BOARD -------------------------------------------------------------------------- 47
[a] USER OPERATION ------------------------------------------------------------------------ 47
[b] SERVICE OPERATION -------------------------------------------------------------------- 47
8. PROTECTORS ---------------------------------------------------------------------------------- 51
[a] INDICATION ---------------------------------------------------------------------------------- 51
ii
[b] PROTECTORS ------------------------------------------------------------------------------ 51
9. ERROR CODES --------------------------------------------------------------------------------- 54
10. PERFORMANCE DATA ---------------------------------------------------------------------- 56
[a] FM-600AHE ---------------------------------------------------------------------------------- 56
[b] FM-600AWHE ------------------------------------------------------------------------------- 57
[c] FMN-440AHE -------------------------------------------------------------------------------- 58
[d] FMN-440AWHE ----------------------------------------------------------------------------- 59
IV. SERVICE DIAGNOSIS ---------------------------------------------------------------------------- 60
1. NO ICE PRODUCTION ------------------------------------------------------------------------- 60
2. LOW ICE PRODUCTION ---------------------------------------------------------------------- 62
3. OTHERS ------------------------------------------------------------------------------------------- 62
V. REMOVAL AND REPLACEMENT OF COMPONENTS ----------------------------------- 64
1. SERVICE FOR REFRIGERANT LINES ---------------------------------------------------- 64
[a] SERVICE INFORMATION ----------------------------------------------------------------- 64
[b] REFRIGERANT RECOVERY ------------------------------------------------------------ 65
[c] EVACUATION AND RECHARGE ------------------------------------------------------- 65
2. BRAZING ------------------------------------------------------------------------------------------ 66
3. COMPRESSOR --------------------------------------------------------------------------------- 67
4. DRIER ---------------------------------------------------------------------------------------------- 68
5. EXPANSION VALVE --------------------------------------------------------------------------- 69
6. WATER REGULATING VALVE - WATER-COOLED MODEL ONLY --------------- 70
7. EVAPORATOR ASSEMBLY ----------------------------------------------------------------- 71
8. CONTROL WATER VALVE ------------------------------------------------------------------ 75
9. FLUSH WATER VALVE ----------------------------------------------------------------------- 76
10. CONTROLLER BOARD ----------------------------------------------------------------------- 77
[a] MODIFICATION ------------------------------------------------------------------------------ 77
[b] REPLACEMENT ---------------------------------------------------------------------------- 77
11. HOT GAS VALVE ------------------------------------------------------------------------------- 78
iii
I. SPECIFICATIONS
1. FEATURES
[a] LOW VOLTAGE
When the supply voltage is too low or surrounding high-current equipment starts up, the
voltage in the icemaker may drop temporarily. In this case, the Compressor will fail to start,
or the Gear Motor will lock during the icemaking operation. The locked Gear Motor may
apply the maximum torque to the icemaking mechanism and damage its parts. To avoid this
trouble, the icemaker will be shut down when the voltage drops. The icemaker will restart
automatically when the proper voltage is restored.
[b] COMPRESSOR STARTUP
If the suction and discharge pressures are unbalanced at startup, the Compressor may fail
to start properly and trip the Thermal Protector. To prevent this failure, the Hot Gas Valve
will open to balance the suction and discharge pressures before the Compressor starts.
[c] ICE PRODUCTION CONTROL (FAN CONTROL) - FMN-440AHE only
The ice production will increase when the condensing pressure in the refrigeration circuit
reduces at low ambient or water temperature. To meet the users’ demands, the icemaker
maximizes ice production at high temperature conditions and minimizes it at low
temperature conditions. To prevent overload on the icemaking mechanism, the icemaker
controls ice production by detecting the condensing temperature and changing the Fan
Motor rotation speed.
[d] OVERLOAD PROTECTION
The auger type icemaker employs the Gear Motor generating a large torque to scrape ice
forming inside the Evaporator. To produce nugget ice, the Extruding Head also requires a
large torque to compress ice. Some use conditions may overload the icemaking
mechanism. The icemaker will detect overload by reduction in Gear Motor rotation speed
and partly bypass the refrigerant flow in the refrigeration circuit. This will temporarily reduce
the ice production to avoid the overload condition.
[e] OVERLOAD ERROR
When the above protection fails to evade the overload condition and the Gear Motor has a
high current and a low rotation speed, the icemaker will shut down for protection. The
icemaking mechanism will have extensive damage, if this condition is repeated ten times. In
this case, the icemaker will display an error code to notify the user of the excessive load on
the icemaking mechanism and the need of its replacement.
1
[f] USER RESET
When a protector trips to shut down the icemaker, an error code will be displayed. If it is a
resettable error, the user can restart the icemaker by pressing the Reset Button accessible
from the Window Panel and continue the icemaking operation until a service person arrives.
Some errors are non-resettable or repetitive and require troubleshooting by qualified
personnel.
[g] ERROR CODES AND RECORDS
When the icemaker shuts down with an error, the Display Window will show an error code
“E_”. A maximum of eight most recent records are memorized and can be checked at the
time of service or inspection.
[h] OTHER INFORMATION
Other information is also available from the Controller Board. See “III. 7. OPERATION
BOARD” for details.
[i] CHANGE OF ICE TYPE
With the older models, changes between flake ice and nugget ice were available by
replacing the Extruding Head and Cutter. With the new models, not only the Extruding Head
and Cutter but also the refrigeration circuit is different between the flake ice model and
nugget ice model. To ensure the proper capacity and prevent a trouble with excessive ice
production, do not replace the Extruding Head and Cutter to change the ice type.
2
2. DIMENSIONS/CONNECTIONS
[a] FM-600AHE, FMN-440AHE
3
[b] FM-600AWHE, FMN-440AWHE
4
3. SPECIFICATIONS
[a] FM-600AHE
AC SUPPLY VOLTAGE
AMPERAGE
STARTING AMPERAGE
ELECTRIC CONSUMPTION
POWER FACTOR
POWER SUPPLY CAPACITY
ICE PRODUCTION PER 24h
1 PHASE 220-240V 50Hz
9.9A
(Ambient temp. 32°C, Water temp. 21°C)
75.9A
1920W
(Ambient temp. 32°C, Water temp. 21°C)
85%
Min 5.0kVA (20.7A)
Approx. 600 kg (Ambient temp. 10°C, Water temp. 10°C)
Approx. 540 kg (Ambient temp. 21°C, Water temp. 15°C)
Approx. 445 kg (Ambient temp. 32°C, Water temp. 21°C)
WATER CONSUMPTION PER 24h Approx. 0.61 m3 (Ambient temp. 10°C, Water temp. 10°C)
Approx. 0.55 m3 (Ambient temp. 21°C, Water temp. 15°C)
Approx. 0.45 m3 (Ambient temp. 32°C, Water temp. 21°C)
SHAPE OF ICE
Flake
MAX. STORAGE CAPACITY
Not Applicable
DIMENSIONS (DRAWING No.)
560(W) x 699(D) x 780(H) (360148)
EXTERIOR
Stainless Steel, Galvanized Steel (Rear)
INSULATION
Polyurethane Foam
CONNECTION - ELECTRIC
Y-type Con.
- WATER SUPPLY
Inlet
G 3/4”
(Connected at rear side)
- DRAIN
Outlet R 3/4” x 2
(Connected at rear side)
ICE MAKING SYSTEM
Auger type
HARVESTING SYSTEM
Direct driven Auger (200W Gear Motor)
COMPRESSOR
Hermetic Compressor Model CS20K6E-PFZ
CONDENSER
Fin and Tube type, Air-cooled (Fan Motor output 30W, 10W)
HEAT REJECTION 2980W (Ambient temp. 32°C, Water temp. 21°C)
EVAPORATOR
Tube coiled around Cylinder (Solder Plated)
REFRIGERANT CONTROL
Thermostatic Expansion Valve
REFRIGERANT CHARGE
R404A 1300g
BIN CONTROL SYSTEM
Actuator and Reed Switch (Time Delay Controlled)
ICE MAKING WATER CONTROL
Float Switch and Water Valve
ICE CAPACITY CONTROL
Hot Gas Bypass
ELECTRICAL PROTECTION
Class I Appliance, 5A Fuse (Microprocessor), Low Voltage
Protection
REFRIGERATION CIRCUIT
Compressor Internal Motor Protector, Internal Pressure Relief
PROTECTION
Valve, Pressure Switch (Auto-reset)
GEAR MOTOR PROTECTION
Thermal Protector (Auto-reset)
Motor Rotation Protection, Current Protection (Manual-reset)
LOW WATER PROTECTION
Float Switch and Microprocessor
BIN CONTROL PROTECTION
Micro Switch (Manual-reset)
INTERLOCK
Shutdown by Microprocessor (Manual-reset)
WEIGHT
Net weight 110 kg / Gross weight 122 kg
PACKAGE
Carton 671mm(W) x 820mm(D) x 915mm(H)
ACCESSORIES
Scoop, Mounting Bracket, Installation Kit
OPERATION CONDITIONS
AMBIENT TEMP.
5-40°C
WATER SUPPLY TEMP.
5-35°C
WATER SUPPLY PRESSURE 0.5-8 bar (0.05-0.8MPa)
VOLTAGE RANGE
Rated Voltage ± 10%
We reserve the right to make changes in specifications and design without prior notice.
5
[b] FM-600AWHE
AC SUPPLY VOLTAGE
AMPERAGE
STARTING AMPERAGE
ELECTRIC CONSUMPTION
POWER FACTOR
POWER SUPPLY CAPACITY
ICE PRODUCTION PER 24h
1 PHASE 220-240V 50Hz
9.0A
(Ambient temp. 32°C, Water temp. 21°C)
75.9A
1670W
(Ambient temp. 32°C, Water temp. 21°C)
81%
Min 5.0kVA (20.7A)
Approx. 600 kg (Ambient temp. 10°C, Water temp. 10°C)
Approx. 560 kg (Ambient temp. 21°C, Water temp. 15°C)
Approx. 520 kg (Ambient temp. 32°C, Water temp. 21°C)
WATER CONSUMPTION PER 24h Approx. 2.70 m3 (Ambient temp. 10°C, Water temp. 10°C)
Approx. 3.10 m3 (Ambient temp. 21°C, Water temp. 15°C)
Approx. 4.40 m3 (Ambient temp. 32°C, Water temp. 21°C)
SHAPE OF ICE
Flake
MAX. STORAGE CAPACITY
Not Applicable
DIMENSIONS (DRAWING No.)
560(W) x 699(D) x 780(H) (360149)
EXTERIOR
Stainless Steel, Galvanized Steel (Rear)
INSULATION
Polyurethane Foam
CONNECTION - ELECTRIC
Y-type Con.
- WATER SUPPLY
Inlet
G 3/4”
(Connected at rear side)
Cond. Inlet
Rc 1/2”
(Connected at rear side)
- DRAIN
Outlet
R 3/4” x 2 (Connected at rear side)
Cond. Outlet Rc 3/8”
(Connected at rear side)
ICE MAKING SYSTEM
Auger type
HARVESTING SYSTEM
Direct driven Auger (200W Gear Motor)
COMPRESSOR
Hermetic Compressor Model CS20K6E-PFZ
CONDENSER
Tube in Tube type, Water-cooled
EVAPORATOR
Tube coiled around Cylinder (Solder Plated)
REFRIGERANT CONTROL
Thermostatic Expansion Valve
REFRIGERANT CHARGE
R404A 680g
BIN CONTROL SYSTEM
Actuator and Reed Switch (Time Delay Controlled)
ICE MAKING WATER CONTROL
Float Switch and Water Valve
Hot Gas Bypass
ELECTRICAL PROTECTION
Class I Appliance, 5A Fuse (Microprocessor), Low Voltage
Protection
REFRIGERANT CIRCUIT
Compressor Internal Motor Protector, Internal Pressure Relief
PROTECTION
Valve, Pressure Switch (Auto-reset)
Discharge Thermostat (Manual-reset)
GEAR MOTOR PROTECTION
Thermal Protector (Auto-reset)
Motor Rotation Protection, Current Protection (Manual-reset)
LOW WATER PROTECTION
Float Switch and Microprocessor
BIN CONTROL PROTECTION
Micro Switch (Manual-reset)
INTERLOCK
Shutdown by Microprocessor (Manual-reset)
WEIGHT
Net weight 110 kg / Gross weight 122 kg
PACKAGE
Carton 671mm(W) x 820mm(D) x 915mm(H)
ACCESSORIES
Scoop, Mounting Bracket, Installation Kit
OPERATION CONDITIONS
AMBIENT TEMP.
5-40°C
WATER SUPPLY TEMP.
5-35°C
WATER SUPPLY PRESSURE 0.5-8 bar (0.05-0.8MPa)
VOLTAGE RANGE
Rated Voltage ± 10%
We reserve the right to make changes in specifications and design without prior notice.
6
[c] FMN-440AHE
AC SUPPLY VOLTAGE
AMPERAGE
STARTING AMPERAGE
ELECTRIC CONSUMPTION
POWER FACTOR
POWER SUPPLY CAPACITY
ICE PRODUCTION PER 24h
1 PHASE 220-240V 50Hz
10.5A
(Ambient temp. 32°C, Water temp. 21°C)
75.9A
1970W
(Ambient temp. 32°C, Water temp. 21°C)
82%
Min 5.0kVA (20.7A)
Approx. 440 kg (Ambient temp. 10°C, Water temp. 10°C)
Approx. 420 kg (Ambient temp. 21°C, Water temp. 15°C)
Approx. 370 kg (Ambient temp. 32°C, Water temp. 21°C)
WATER CONSUMPTION PER 24h Approx. 0.45 m3 (Ambient temp. 10°C, Water temp. 10°C)
Approx. 0.43 m3 (Ambient temp. 21°C, Water temp. 15°C)
Approx. 0.38 m3 (Ambient temp. 32°C, Water temp. 21°C)
SHAPE OF ICE
Nugget
MAX. STORAGE CAPACITY
Not Applicable
DIMENSIONS (DRAWING No.)
560(W) x 699(D) x 780(H) (360150)
EXTERIOR
Stainless Steel, Galvanized Steel (Rear)
INSULATION
Polyurethane Foam
CONNECTION - ELECTRIC
Y-type Con.
- WATER SUPPLY
Inlet
G 3/4”
(Connected at rear side)
- DRAIN
Outlet R 3/4” x 2
(Connected at rear side)
ICE MAKING SYSTEM
Auger type
HARVESTING SYSTEM
Direct driven Auger (200W Gear Motor)
COMPRESSOR
Hermetic Compressor Model CS20K6E-PFZ
CONDENSER
Fin and Tube type, Air-cooled (Fan Motor output 30W, 10W)
HEAT REJECTION 2980W (Ambient temp. 32°C, Water temp. 21°C)
EVAPORATOR
Tube coiled around Cylinder (Solder Plated)
REFRIGERANT CONTROL
Thermostatic Expansion Valve
REFRIGERANT CHARGE
R404A 1110g
BIN CONTROL SYSTEM
Actuator and Reed Switch (Time Delay Controlled)
ICE MAKING WATER CONTROL
Float Switch and Water Valve
ICE CAPACITY CONTROL
Hot Gas Bypass, Fan Speed Control
ELECTRICAL PROTECTION
Class I Appliance, 5A Fuse (Microprocessor), Low Voltage
Protection
REFRIGERATION CIRCUIT
Compressor Internal Motor Protector, Internal Pressure Relief
PROTECTION
Valve, Pressure Switch (Auto-reset)
GEAR MOTOR PROTECTION
Thermal Protector (Auto-reset)
Motor Rotation Protection, Current Protection (Manual-reset)
LOW WATER PROTECTION
Float Switch and Microprocessor
BIN CONTROL PROTECTION
Micro Switch (Manual-reset)
INTERLOCK
Shutdown by Microprocessor (Manual-reset)
WEIGHT
Net weight 110 kg / Gross weight 122 kg
PACKAGE
Carton 671mm(W) x 820mm(D) x 915mm(H)
ACCESSORIES
Scoop, Mounting Bracket, Installation Kit
OPERATION CONDITIONS
AMBIENT TEMP.
5-40°C
WATER SUPPLY TEMP.
5-35°C
WATER SUPPLY PRESSURE 0.5-8 bar (0.05-0.8MPa)
VOLTAGE RANGE
Rated Voltage ± 10%
We reserve the right to make changes in specifications and design without prior notice.
7
[d] FMN-440AWHE
AC SUPPLY VOLTAGE
AMPERAGE
STARTING AMPERAGE
ELECTRIC CONSUMPTION
POWER FACTOR
POWER SUPPLY CAPACITY
ICE PRODUCTION PER 24h
1 PHASE 220-240V 50Hz
9.6A
(Ambient temp. 32°C, Water temp. 21°C)
75.9A
1850W
(Ambient temp. 32°C, Water temp. 21°C)
84%
Min 5.0kVA (20.7A)
Approx. 440 kg (Ambient temp. 10°C, Water temp. 10°C)
Approx. 415 kg (Ambient temp. 21°C, Water temp. 15°C)
Approx. 380 kg (Ambient temp. 32°C, Water temp. 21°C)
WATER CONSUMPTION PER 24h Approx. 1.70 m3 (Ambient temp. 10°C, Water temp. 10°C)
Approx. 2.00 m3 (Ambient temp. 21°C, Water temp. 15°C)
Approx. 2.60 m3 (Ambient temp. 32°C, Water temp. 21°C)
SHAPE OF ICE
Nugget
MAX. STORAGE CAPACITY
Not Applicable
DIMENSIONS (DRAWING No.)
560(W) x 699(D) x 780(H) (360151)
EXTERIOR
Stainless Steel, Galvanized Steel (Rear)
INSULATION
Polyurethane Foam
CONNECTION - ELECTRIC
Y-type Con.
- WATER SUPPLY
Inlet
G 3/4”
(Connected at rear side)
Cond. Inlet
Rc 1/2”
(Connected at rear side)
- DRAIN
Outlet
R 3/4” x 2 (Connected at rear side)
Cond. Outlet Rc 3/8”
(Connected at rear side)
ICE MAKING SYSTEM
Auger type
HARVESTING SYSTEM
Direct driven Auger (200W Gear Motor)
COMPRESSOR
Hermetic Compressor Model CS20K6E-PFZ
CONDENSER
Tube in Tube type, Water-cooled
EVAPORATOR
Tube coiled around Cylinder (Solder Plated)
REFRIGERANT CONTROL
Thermostatic Expansion Valve
REFRIGERANT CHARGE
R404A 570g
BIN CONTROL SYSTEM
Actuator and Reed Switch (Time Delay Controlled)
ICE MAKING WATER CONTROL
Float Switch and Water Valve
Hot Gas Bypass
ELECTRICAL PROTECTION
Class I Appliance, 5A Fuse (Microprocessor), Low Voltage
Protection
REFRIGERANT CIRCUIT
Compressor Internal Motor Protector, Internal Pressure Relief
PROTECTION
Valve, Pressure Switch (Auto-reset)
Discharge Thermostat (Manual-reset)
GEAR MOTOR PROTECTION
Thermal Protector (Auto-reset)
Motor Rotation Protection, Current Protection (Manual-reset)
LOW WATER PROTECTION
Float Switch and Microprocessor
BIN CONTROL PROTECTION
Micro Switch (Manual-reset)
INTERLOCK
Shutdown by Microprocessor (Manual-reset)
WEIGHT
Net weight 110 kg / Gross weight 122 kg
PACKAGE
Carton 671mm(W) x 820mm(D) x 915mm(H)
ACCESSORIES
Scoop, Mounting Bracket, Installation Kit
OPERATION CONDITIONS
AMBIENT TEMP.
5-40°C
WATER SUPPLY TEMP.
5-35°C
WATER SUPPLY PRESSURE 0.5-8 bar (0.05-0.8MPa)
VOLTAGE RANGE
Rated Voltage ± 10%
We reserve the right to make changes in specifications and design without prior notice.
8
4. CONSTRUCTION
Control Box
Front
Expansion Valve
Flush Water Valve
Hot Gas Valve
Right Side
Compressor
Condenser
Drier
Control Water Valve
Reservoir
Left Side
Ice Chute
Evaporator
Gear Motor
9
II. MAINTENANCE AND CLEANING INSTRUCTIONS
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 (Top Bearing)
Housing (Lower Bearing)
Mechanical Seal
These parts should be inspected at least once a year or every 10,000 hours of
operation. Their service life ultimately depends on water quality and environment,
therefore more frequent inspection and maintenance may be required.
1. EXTRUDING HEAD, HOUSING BEARING, AUGER BEARING
These parts should be replaced if a diametrical gap of more than 0.5 mm is found when at least
three spots are checked by changing the direction of the Auger on each Bearing.
It depends on the water quality and conditions, but normally the Bearings should be checked for
wear after a total of 8,000 - 10,000 hour operation from installation date.
Note: The clearance between the Auger blades and the Evaporator interior is 0.4 - 0.5 mm. If
the Bearings and rotating parts are worn out to create a larger clearance, the Evaporator
interior may be damaged. (The diameters differ by 0.8 - 1.0 mm.)
If the Auger surfaces against which the Bearings contact are no longer smooth or show
any burrs or abrasions during the above inspection, replace the auger.
2. MECHANICAL SEAL
The Mechanical Seal prevents water leaks from between the Auger and the Housing Bearing
and gradually wears out to reduce its watertightness. Check the amount of water leakage from
the Drain Pipe located at the side of the Gear Case to determine the necessity of replacement.
Total operation time
3,000 hours
10,000 hours
Water leakage
0.1 mL/h
0.5 mL/h
Note: The water leakage will exceed the above amount with scale/dirt build up or damage on
the mating surface. Replace the Mechanical Seal when the water leakage exceeds 0.5
mL/h.
10
3. GEAR MOTOR
After the following hours of operation, check the Gear Motor for excessive noise caused by
increased torque or deterioration of mechanical parts.
Bearing, Gear and other mechanical parts:
Oil seal:
10,000 hours
5 years
Note: When the output shaft oil seal is exposed to a large amount of water at one time, water
may enter the Gear Case. Always drain the water circuit before removing the Auger for
service.
4. CONDENSER
Check the Condenser once a year, and clean if required by using a brush or vacuum cleaner.
More frequent cleaning may be required depending on the location of the icemaker.
5. 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. Remove and
clean the Air Filter at least twice per month:
1) Slide the Air Filter off the Louver.
2) Clean the Air Filter by using a vacuum cleaner. When
severely clogged, use warm water and a neutral
cleaner to wash the Air Filter.
Air Filter
3) Rinse and dry the Air Filter thoroughly, and place it in
position.
11
Louver
6. WATER VALVE
1) Disconnect the power source.
2) Close the water supply tap.
3) Disconnect the Inlet Hose from the Water Valve.
4) Remove the Mesh Filter from the Water Valve.
5) Clean the Mesh using a brush.
6) Replace the Mesh and Inlet Hose in their correct positions.
7) Open the water supply tap.
8) Connect the power source.
9) Check for leaks.
Coil
Do not remove
Filter
Inlet Hose
Packing
12
7. CLEANING OF WATER SYSTEM
WARNING
1. HOSHIZAKI recommends cleaning this unit at least twice a year. More frequent
cleaning, however, may be required in some existing water conditions.
2. Do not touch the Operation Switch with damp hands.
3. Always wear rubber gloves, eye protectors, apron, etc. for safe handling of the
cleaner and sanitiser.
4. Use the cleaners and sanitisers recommended by Hoshizaki. Contact your
local Hoshizaki office for further details. (The instructions below give an example
of those recommended cleaners and sanitisers.)
5. Never mix cleaning and sanitising solutions in an attempt to shorten cleaning
time.
6. Wipe off any splashed or spilt cleaner/sanitiser immediately.
7. Do not use any ammonia type cleaners on any part of the icemaker.
<STEP 1>
Dilute the solutions with water as follows:
Cleaning solution: “Nickel-Safe Ice Machine Cleaner” by The Rectorseal Corporation or similar.
Prepare approximately 3 L of solution as directed on the container.
Sanitising solution: 30 mL of 5.25% sodium hypochlorite with 7.6 L of water or the Hoshizaki
recommended sanitiser as directed on the container.
IMPORTANT
For safety and maximum effectiveness, use the solutions immediately after dilution.
<STEP 2>
Use the cleaning solution to remove lime deposits in the water system.
1) Open the Plastic Access Flap on the Front Panel.
2) Press the Stop Button to activate the flush cycle (approx. 10 minutes).
3) Remove all ice from the Storage Bin to avoid contamination by the cleaner.
13
4) Unplug the icemaker. Remove the Top and Front Panels.
5) Remove the Cover of the Reservoir. Remove any loose debris or scale.
6) Carefully fill the Reservoir with the solution to the overflow point. If necessary, use a small
brush to clean the inside of the Reservoir.
7) Refit the Reservoir Cover.
8) Check that the Operation Switch is in the “RUN” position.
9) Loose fit the Front and Top Panels.
10) Allow the icemaker to stand for about 10 minutes, then plug in the icemaker to make ice with
the solution.
11) With the water supply tap open, allow the machine to continue icemaking for a further 20
minutes. Open the Access Flap and press the Stop Button.
12) Allow time for the Gear Motor to stop and the water system to drain.
13) Unplug the icemaker.
14) Refit the Top and Front Panels. Plug in the icemaker.
15) Allow the icemaker to make ice for approximately 10 minutes.
16) Pour warm water into the Storage Bin to melt any ice down the drain.
Note: 1. If the machine has heavy deposits of scale, repeat the complete cleaning procedure.
2. Do not increase the proportion of cleaning solution to shorten cleaning times, as this
may lock the Auger when completing item 10).
<STEP 3>
Note: Sanitising should always be completed after cleaning or alternately as an individual
procedure if conditions exist to make it necessary.
Use 2.8 lit. of the sanitising solution to sanitise the icemaker.
17) Follow items 1) to 16) to complete sanitisation of the water system.
14
8. PERIODICAL CLEANING
1) Machine and Bin Exterior
Wipe the exterior at least once per week with a clean, soft cloth. Use a damp cloth containing a
neutral cleaner to wipe off grease or dirt.
2) Storage Bin Interior Cleaning/Sanitisation (as required)
1) Open the Storage Bin Door, and remove all ice.
2) Wash the Bin Liner, Ice Deflector and Door inner surface with a neutral non-abrasive cleaner.
Rinse thoroughly with a clean cloth and fresh water.
3) Mix 5 litres of water with 18 mL of 5.25% sodium hypochlorite solution in a suitable container
or the recommended Hoshizaki sanitiser as directed.
4) Soak a clean sponge or cloth with the solution and wipe all the surfaces of the Bin Liner, Ice
Deflector and Door inner surface.
5) Rinse thoroughly with fresh water and a clean cloth to wipe off the solution. Close the Bin
Door.
Note: Some solutions may cause damage to the Bin liner surfaces or corrosion on the metal
parts. Always rinse the sanitiser unless directed otherwise by Hoshizaki guidelines.
15
III. TECHNICAL INFORMATION
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT
[a] FM-600AHE
Pressure Switch
Cut-out
2.85 + 0.15/0 MPa
Cut-in
2.30 ± 0.15 MPa
16
[b] FM-600AWHE
Pressure Switch
Cut-out
2.65 + 0.15/0 MPa
Cut-in
2.20 + 0.15/0 MPa
17
[c] FMN-440AHE
Pressure Switch
Cut-out
2.85 + 0.15/0 MPa
Cut-in
2.30 ± 0.15 MPa
18
[d] FMN-440AWHE
Pressure Switch
Cut-out
2.65 + 0.15/0 MPa
Cut-in
2.20 + 0.15/0 MPa
19
2. WIRING DIAGRAM
[a] WIRING DIAGRAM
20
[b] CONTROL BOX LAYOUT
21
3. ICEMAKING MECHANISM
[a] EVAPORATOR (CASING)
The Evaporator consists of a stainless steel icemaking cylinder coiled with a refrigeration
pipe and wrapped together with a polyurethane foam insulation material. Water coming
from the inlet into the Evaporator will be frozen into ice. The Ice Spout is located on top of
the Evaporator. The Deicing Heater (Aluminum Cast Heater) around the top of the
cylinder functions to reduce the load on the Gear Motor. See “5. REFRIGERATION
CIRCUIT” for further details.
[b] AUGER
The stainless steel Auger is supported by the upper and lower Bearings of the Evaporator
and slowly rotated by the Gear Motor, while scraping off the ice forming on the inner wall of
the Cylinder and pushing up to the Ice Spout.
[c] EXTRUDING HEAD (BEARING)
The stainless steel Extruding Head is provided with a press-fit plastic Bearing inside and
22
fixed on top of the Evaporator. The Extruding Head functions as the Auger Bearing and
compresses the sherbet ice carried up by the Auger into a column shape with the path
resistance.
[d] HOUSING
The cast bronze Housing is provided with a press-fit plastic Bearing inside and fixed on the
bottom of the Evaporator for connection with the Gear Motor.
[e] MECHANICAL SEAL
The Mechanical Seal on the lower Auger Bearing prevents icemaking water leaks into the
Evaporator. The mating surfaces are made of ceramic and carbon.
[f] COUPLING (SPLINE JOINT)
The Auger bottom and Gear Motor output shaft are splined and connected with the Spline
Joint.
[g] GEAR MOTOR
The Gear Motor consists of a 1 phase 240V drive motor integrated with a decelerator and
provided with a built-in auto-reset Thermal Protector. When the Thermal Protector trips,
the Controller Board will stop the Gear Motor. The Protector can be reset by the Reset
Button on the Operation Board. The Thermal Protector trips when the Gear Motor
mechanism is overloaded or when excessively high or low voltage is applied on the Gear
Motor. The electrical capacity must be increased if a large current flows through the
surrounding equipment.
[h] DEICING HEATER (ALUMINUM CAST HEATER)
The Deicing Heater is provided to reduce the load of ice passing the Extruding Head during
a freeze cycle and to prevent vapor lock during a flush cycle. Compared with the
conventional Cord Heater or Belt Heater, the Deicing Heater has a larger contact area with
the Evaporator to ensure more efficient reduction of the load.
[i] REMOVABLE FLANGE
The Flange used to be welded on the Evaporator to fix the Spout. But sometimes the
Extruding Head applies excessive load on the Evaporator to compress ice, resulting in
breaking the welded joints. To avoid the load, the Flange has been changed to a separate
part to be secured together with the Extruding Head by using a socket head cap screw.
23
[j] SOCKET HEAD CAP SCREW
Sometimes the icemaking operation may produce white solids on the Drip Pan. They are
deposits of silica and calcium contents in the icemaking water leaking from the socket head
cap screw. The screw is provided with retaining and sealing functions, which may be
reduced by the load and vibration during a freeze cycle. Do not reuse a removed socket
head cap screw.
Solids deposited from
socket head cap screw
24
4. WATER CIRCUIT
[a] RESERVOIR (WATER TANK)
The Reservoir made of plastic maintains the water level necessary for ice production.
[b] FLOAT SWITCH
The Reservoir is provided with a plastic Float Switch to detect the water level. The floats
move up and down along with the water level and send ON/OFF signals to open/close the
Water Valve in order to maintain the proper water level.
If the proper water level cannot be resumed within a specific time after the Float Switch
sends an OFF signal, the icemaker will detect a low water condition and shut down. The
icemaker will automatically restart icemaking operation when the proper water level is
resumed.
If the Float Switch trips at the upper float level on startup and trips at the lower float level
(request for water supply) before the Compressor starts, the icemaker will display “E0” for a
water leak error and shut down.
If the Float Switch trips at the upper float level and does not trip at the lower float level, the
icemaker will display “E1” for a low ice production error and shut down.
If the Float Switch trips at both upper (fill) and lower (empty) float levels, the icemaker will
display “E2” for a switch contact error and shut down.
See “9. ERROR CODES” for details.
[c] CONTROL WATER VALVE
The Control Water Valve located above the Reservoir will open to supply water to the
Reservoir when the coil is energized. Despite the water pressure varying from 0.5 bar to 8
bar at the water supply inlet, the built-in flow controller maintains almost the same water
flow (24V AC).
[d] FLUSH WATER VALVE
When the Flush Timer operates or the Stop Button is pressed to shut down the icemaker,
the Flush Water Valve will be energized to open and flush out the Evaporator Casing and
Reservoir (21.7V DC).
[e] WATER REGULATOR
See “5. REFRIGERATION CIRCUIT”.
[f] DRAINING ICEMAKER IN SUBFREEZING CONDITIONS
In winter, the water circuit (including the Condenser for water-cooled model) must be
completely drained out or otherwise protected to prevent freeze-up and damage before
25
shutting down the icemaker at night.
Drain
Air Shut-off Valve
Air or CO2
Union
Union
Tee
Water Supply Line Shut-off Valve
Water Supply
a) Water-cooled Model
1)
2)
3)
4)
5)
6)
7)
Operate the icemaker in the ICE mode.
Close the Water Supply Line Shut-off Valve to stop water supply.
Open the Air Shut-off Valve.
Blow the Water-cooled Condenser out using compressed air or CO2.
The sound of draining water is heard from the Water-cooled Condenser.
Press the Stop Button, and drain the Float Tank and Evaporator Casing.
Turn off the icemaker.
Before restarting the icemaker:
1. Close the Air Shut-off Valve.
2. Open the Water Supply Line Shut-off Valve.
26
b) Air-cooled Model
Follow the above steps 2), 3), 6) and 7).
c) Operation of Water Regulator
When the Water Supply Line Shut-off Valve is closed, no cooling water will flow into the
Condenser, raising the condensing pressure. Then, the Water Regulator will open wider
to increase the cooling water flow. If air is sent from the water inlet in this condition, the
water remaining inside the Condenser will drain out through the wide-open Water
Regulator.
If the icemaker is shut down, the Water Regulator is closed with a low condensing pressure.
Sending air in this condition will not drain the water from the Condenser.
27
5. REFRIGERATION CIRCUIT
[a] APPLICABLE PARTS
Refrigerant (R404A)
Compressor
Evaporator Casing
Air-cooled Condenser
Water-cooled Condenser
Air-cooled Condenser
Fan Motor
Water Regulator
Drier
Solenoid Valve
Strainer
Thermal Expansion Valve
(with MOP)
Access Valve
Heat Exchanger
FM-600AHE
x
x
x
x
FM-600AWHE
x
x
x
FMN-440AHE
x
x
x
x
x
x
(2 pcs)
FMN-440AWHE
x
x
x
x
x
(1 pc)
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
[b] SERVICE INSTRUCTIONS
Always restore the original bindings after servicing the refrigeration circuit. Otherwise,
vibration may cause overstress and damage to the circuit, resulting in refrigerant leak.
After replacing the Evaporator or Auger, run the icemaker for 30 minutes to produce ice,
check for impurities, and discard.
[c] REFRIGERANT CONTROL (Compressor Cooling)
1) Control Method
FM-600AHE
FM-600AWHE
FMN-440AHE
FMN-440AWHE
Liquid Bypass
x
Fan Cooling
x
x
x
x
See “1. WATER AND REFRIGERANT CIRCUIT”.
2) Liquid Bypass
A small amount of high-pressure liquid refrigerant constantly flows in the suction line to
prevent the Compressor from overheating.
28
3) Fan Cooling
The Fan Motor blows air over the Compressor to release its heat.
[d] REFRIGERANT CONTROL (Ice Production Control)
1) Control Method
Fan Speed Control
FM-600AHE
FM-600AWHE
FMN-440AHE
FMN-440AWHE
Hot Gas Bypass
x
2) Fan Speed Control
Increased ice production in a low temperature condition will overload and damage the
icemaking mechanism. To control the ice production, the Controller Board energizes and
de-energizes the Fan Motor to reduce its rotation speed.
3) Hot Gas Bypass
The water-cooled or other models with no Fan Motor will bypass a small amount of hot gas
to the suction line to reduce ice production in a low temperature condition.
[e] REFRIGERANT CONTROL (Overload Control)
1) Control Method
All models:
Hot gas bypass
2) Hot Gas Bypass
Each model controls ice production to prevent icemaking overload. But depending on the
field conditions or component variation, the icemaker may be overloaded, resulting in
reduction of the Gear Motor rotation speed or rise in the current. In this case, hot gas will
be bypassed to the suction line to instantaneously avoid overload.
[f] REFRIGERANT
The icemaker employs refrigerant R404A which itself is not flammable or poisonous.
However, a small room filled with R404A may cause suffocation with a lack of oxygen.
Also, when exposed to an open flame, R404A creates Phosgene gas, hazardous in large
amounts. Handle the refrigerant in a well-ventilated area with no flames.
29
Always recover the refrigerant and store it in a proper container, if required by an applicable
law. Do not discharge the refrigerant into the atmosphere.
[g] COMPRESSOR
The Compressor absorbs the low-pressure refrigerant gas vaporized in the Evaporator (to
reduce the pressure inside the Evaporator), compresses the refrigerant into
high-temperature high-pressure gas, and sends it out to the Condenser.
The hermetic-type Compressor is efficient in refrigeration, and the refrigeration circuit is
designed to endure long hours of operation. The Compressor is mounted on vibration
damping rubber to prevent transmission of vibration. In case of accidental overload, the
Case Thermostat or Overload Relay will shut down the Compressor. The Reset Button
must be pressed to reset the Overload Relay.
[h] EVAPORATOR CASING
The Evaporator Casing is a thin and rigid stainless steel pipe tightly coiled around with a
copper tube and solder finished. The refrigerant flows through a very narrow path in the
Expansion Valve with a sudden drop of pressure and evaporates by absorbing heat of
vaporization from the Evaporator Casing. The water supplied inside the Evaporator
Casing is deprived of heat and forms ice film which will be scraped and moved up by the
Auger.
[i] CONDENSER
The Condenser refrigerates and liquefies the high-temperature high-pressure refrigerant
gas discharged from the Compressor into high-pressure liquid refrigerant. The Condenser
is either air-cooled or water-cooled.
A dirty Condenser will significantly reduce the refrigeration efficiency and performance, and
will also shorten the service life of the components (especially refrigeration circuit). The
Condenser must be cleaned according to the following instructions. The frequency of
cleaning depends on the installation conditions.
a) Air-cooled Condenser (Fin-and-tube type)
A copper tube is attached on a finned aluminum plate with high heat conductivity to promote
heat radiation, and a Fan Motor is also provided for forced air cooling. A remote type
Condenser is also available to protect the interior from noise of the Fan Motor and
temperature rise by heat radiation.
Use a vacuum cleaner or brush to remove dirt and dust between the fins. Be careful not to
bend the fins.
b) Water-cooled Condenser (Tube-in-tube type)
Cooling water flows in the inner tube and refrigerant gas flows in the outer tube in opposite
directions (counterflow) for efficient heat exchange. The valve position of the Water
Regulator is automatically controlled to regulate the discharge pressure in the refrigerant
30
circuit and change the flow rate of cooling water.
Scale, slime and corrosion will affect heat exchange. Scale such as silica and iron oxide is
the most common cause of problems and must be removed if any. Dissolve a scale
remover in cold or warm water, and chemically remove scale inside the Condenser by
either of the following procedures:
< Procedure 1 >
Leave the above cleaning solution inside the Condenser for 12 hours.
< Procedure 2 >
1) Prepare the following:
Pump Motor-----------------May be used for another icemaker.
Dissolving Tank ------------Holds at least 10L plastic bucket.
Connecting Hose ----------Vinyl hose ø9 x ø15 x 1.5m (x 2)
Cold or warm water -------10L (50°C water is most effective)
Scale Remover-------------Appropriate amount
Note: The cleaning procedure may vary depending on the remover used. Follow the
instructions of the manufacturer.
2)
3)
4)
5)
6)
7)
8)
9)
Others ------------------------W16 Flare Nut (x 2), Wire, Connecting Pipe (with one flared
end, x 2)
Remove the cabinet, and check the Condenser joint for corrosion or water leak.
Disconnect the flare nuts at the Condenser inlet and outlet
To prepare a circulation circuit, connect the Condenser outlet (top) with the hose to the
Tank and the Condenser inlet (bottom) with the hose from the Pump Motor.
Operate the Pump Motor to clean the Condenser.
Circulate the solution for 0.5 - 2 hours, depending on the amount of scale. The solution
may turn reddish black in 30 minutes with dissolved scale. It will not reattach during
circulation. Also, the solution may bubble in the Dissolving Tank by chemical reaction,
which will not affect cleaning.
After cleaning, rinse the circuit until the water becomes clear.
After rinsing, reconnect the Condenser, and restart the icemaker.
The cleaning effect should be checked by the amount of scale dissolved during the
circulation cleaning or by comparison of suction and discharge pressures and cooling
water amount between before and after the cleaning.
[j] CONDENSER COOLING FAN MOTOR
The Fan Motor cools the Air-cooled Condenser and sends air to condense refrigerant gas
inside the Condenser.
[k] WATER REGULATOR
The Water Regulator controls the water flow in the Water-cooled Condenser to maintain a
certain level of the discharge pressure. The discharge pressure may rise at startup but
stabilize in 30 minutes.
31
The Water Regulator is factory-adjusted. No adjustment is required under normal use
except for replacement of the FM-600AWHE Water Regulator. 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 center temperature.
2) After 5 minutes of ice production, the pressure gauge should read 14.8 bar or the
thermometer read 32 - 34°C, or 18.6 bar or 41 - 43°C for FMN-440AWHE. If the
readings are lower, use a flat blade screwdriver to adjust the screw in a
counterclockwise direction. If the readings are higher, adjust in a clockwise direction.
Adjust the screw by a half turn only each time and recheck the readings before making
further adjustments.
3) Check that the pressure or the condenser center temperature remains steady at the
recommended settings before removing the gauge or thermometer.
Model
FM-600AWHE
FMN-440AWHE
Discharge Pressure (Condensing Temp.)
14.8 bar (32 - 34°C)
18.6 bar (41 - 43°C)
Adjustment required
Factory adjustment
[l] DRIER
The Drier uses desiccants (molecular sieves + activated alumina) to absorb moisture in the
refrigeration circuit. The built-in filter also corrects foreign matter in the refrigeration circuit
to prevent troubles with valves clogged with dirt or moisture.
[m] SOLENOID VALVE
The Solenoid Valve controls the liquid injection and hot gas bypass flow rates.
32
[n] THERMOSTATIC EXPANSION VALVE
The Expansion Valve throttles high-pressure liquid refrigerant into low-temperature
low-pressure state by adiabatic expansion and maintains the proper amount of refrigerant
supply depending on the Evaporator load. The Thermostatic Expansion Valve controls the
valve position to regulate the superheat (difference between evaporating temperature and
suction gas temperature). No superheat control is available from outside.
To check the Expansion Valve for proper operation, remove the Bulb while the Compressor
is running. If the suction pressure rises, the Expansion Valve is working normally.
Note: Do not leave the Bulb removed for a long time while the Compressor is running.
The Compressor may fail due to liquid return.
[o] ACCESS VALVE
The Access Valve connects the inside and outside of the refrigeration circuit to allow
evacuation, recharge, and pressure measurement.
Note: When replacing (brazing) the Access Valve, remove the valve core to prevent the
rubber part from melting. The valve is sealed by the core only. Always cap the valve
while not in use. Tighten the seal nut to the torque of 9.81 - 12.26Nm to prevent gas
leaks.
33
6. ELECTRIC CIRCUIT
CAUTION
Reassemble all the components as they were after servicing the unit according to a
service call.
[a] BASIC OPERATION
The icemaker starts water supply when the Operation Switch is turned ON. On completion
of water supply, the Gear Motor starts immediately, and the Solenoid Valve opens to
balance the suction and discharge pressures. After 5 minutes the Compressor starts to
begin icemaking operation. The Solenoid Valve stays open for another 3.5 minutes.
In normal operation, the icemaker shuts down when the Storage Bin fills up to trip the Bin
Control Switch or the Stop Button is pressed. When the Compressor operates for 6 hours
in total and continuously for more than 10 minutes, the icemaker supplies water until the
Reservoir fills up and starts a drain cycle. After 10 minutes the icemaker automatically
starts water supply and resumes icemaking operation.
The FMN-440AHE icemaker is equipped with fan speed control. It monitors the
condenser center temperature and slows down the fan rotation to regulate the condensing
pressure. This function is to prevent a mechanical trouble with overproduction of ice.
The Aluminum Cast Heater is tightly fit to the Evaporator Casing for heat transfer. During
icemaking operation, the Heater is deprived of heat and becomes colder than the ambient
temperature. When the voltage rises, the Heater output increases with the square of the
voltage. To prevent overheat, if the monitored voltage becomes too high, the Heater is
instantly de-energized (for clipping voltage waveform) to control the output within the
applicable range.
34
[b] TIMING CHART
35
[c] SEQUENCE
(1) Startup - Water Supply
36
(2) Startup - After completion of water supply, Gear Motor and Fan Motor start (5
min).
37
(3) Startup – Ice production starts (Hot Gas Valve ON).
38
(4) Normal Operation - Ice Production (Hot Gas Valve OFF)
* See (3) for operation with Hot Gas Valve ON.
39
(5) Normal Operation - Bin Control
40
(6) Shutdown - Compressor stops (5 min)
41
(7) Shutdown - Drain
42
[d] OPERATION BOARD
The Operation Board is provided for operation of the icemaker. See “7. OPERATION
BOARD” for details.
[e] CONTROLLER BOARD
The icemaker is controlled by the Controller Board based on the following logic:
1) Low Voltage Standby
In a low voltage condition, the Compressor and Gear Motor may fail to start or rotate
properly due to insufficient torque. This could result in a twisted Evaporator. The
icemaker will stop icemaking operation until the proper voltage is restored.
2) Ice Production Control
In a low ambient or water temperature condition, the ice production capacity will increase.
Then, the Gear Motor will have a larger torque to scrape off ice, which will overload the
entire icemaking mechanism. To prevent overload, the FM-440AHE icemaker controls the
fan rotation speed.
3) Overload Prevention
Despite the above control, the icemaker may be overloaded depending on the field
conditions (ex. water quality) or dimensional variation of the components. An overload
condition will decelerate the Gear Motor or raise the current. On detection of these
conditions, the refrigerant will bypass the Evaporator to temporarily reduce ice production.
When unloaded, the icemaker will stop bypassing and resume the usual icemaking
operation.
4) Overload Protection
If the above control cannot unload the icemaker, it will shut down before leading to critical
and costly problems, such as with the icemaking mechanism.
5) Error Code Indication
When the icemaker shuts down with a trouble, an error code will be displayed immediately
to notify the user. To facilitate servicing, ask the user for the applicable error code, and
prepare for the trouble in advance.
43
6) Flush Timer
The previous models were equipped with a Flush Timer that periodically flushes the water
circuit to prevent water deposits from entering the Bearing and accelerating its wear. The
latest models have the Controller Board provided with this function of the Flush Timer.
During the flush cycle, the Display Window on the Operation Board will illuminate “DRAIN”.
As the auger type icemaker continuously produces ice, the content of substances included
in the icemaking water inside the Evaporator Casing is three to five times as high as that in
the supplied water. As a result, substances such as calcium, magnesium, and silica
contained in water will attach and deposit inside the Evaporator Casing to reduce the ice
production capacity or accelerate wear on the moving parts.
[f] SURGE ABSORBER
The Surge Absorber is provided to protect the Controller Board from lightning.
[g] CAPACITOR - XY FILTER
The Capacitor - XY Filter is provided to prevent the Controller Board from signal errors
caused by internal and external noises.
[h] BIN CONTROL SWITCH
The Bin Control Switch is composed of a Proximity Switch and Actuator. When the Chute
fills up, ice will push up the Actuator on top of the Chute to switch off the Proximity Switch.
After 7 seconds, the Controller Board will stop the Gear Motor and Compressor at the same
44
time. When ice is used, the Actuator will return to the original position to switch on the
Proximity Switch. The Gear Motor will restart in 7 seconds, and the Compressor in 5
minutes.
When the Bin Control Switch seems to have malfunctioned, check the dimensions of the
Actuator as well as the operation of the Proximity Switch. Also, if the Chute Switch or the
Gear Motor Circuit Protector has operated for some unidentified reason, be sure to check
the Actuator for proper dimensions.
1) Remove the Bin Control Switch from the Chute.
2) Move the Actuator to the maximum operation angle as shown below (top). Check that
the Actuator is about 13 mm away from the Barrier. If not, replace the whole Bin
Control Switch assembly.
[i] CHUTE SWITCH
The Chute Switch consists of a microswitch and a band securing the Spout and Chute.
When the Bin Control Switch breaks down, the band opens and presses the button on the
microswitch (contacts open) to stop the icemaker (error code: EL).
To restart the icemaker, remove ice from the Spout and Chute, and move the Operation
Switch to the “STOP” position, then to the “RUN” position.
45
Normal Condition
Band
Microswitch
Chute
Spout
Abnormal Condition
(Band moves and presses microswitch)
Band
Microswitch
Chute
Spout
[j] DEICING HEATER (ALUMINUM CAST HEATER)
The Deicing Heater is provided to reduce the load of ice passing the Extruding Head and
prevent vapor lock. If the Extruding Head is clogged with ice, a creaking sound will be
heard, or the Evaporator Cylinder will expand to break the soldered joint between the
Cylinder and Copper Tube, where condensate may enter and freeze to crush the Copper
Tube. In the previous models, the Flange was welded to secure the Spout, which may
cause cracked welded joints. The latest models are provided with an Aluminum Cast
Heater to improve attachment and heat transfer to the Cylinder compared to the
conventional Cord Heater or Belt Heater. The Heater is equipped with a Thermostat
(60°C) containing a built-in Thermal Fuse (98°C) for overheat protection.
[k] CRANKCASE HEATER
Equipments employing a large amount of refrigerant are provided with the Crankcase
Heater to prevent refrigerant migration to the Compressor during off-cycles resulting in oil
shortage at startup. The Crankcase Heater will be energized also when the user turns off
the Operation Switch on the Operation Board.
[l] SOLENOID VALVE (BYPASS CONTROL)
See “5. REFRIGERATION CIRCUIT”.
46
7. OPERATION BOARD
Visible from
Window Panel
[a] USER OPERATION (accessible from the Window Panel)
ICE = When pressed in the STOP mode, the unit will be supplied with water and start
icemaking operation.
STOP = When pressed in the ICE mode, the unit will stop icemaking operation and drain.
RESET = When pressed during shutdown with an error code displayed, the unit may restart
icemaking operation. Unless the cause of the error is removed, the unit may stop again
with the error code returned.
OPERATION SWITCH = Power supply for the icemaker. Turn it OFF to shut down the unit
for a long time. The Crankcase Heater will remain energized after the switch is turned
OFF.
[b] SERVICE OPERATION (Remove the Front Panel for access to the Option and Set
Buttons)
CAUTION
Removal of the Front Panel will expose moving and hot parts. It is allowed for qualified
service personnel only.
1) Setting Model No.
The Model Setting No. must be set at the time of replacement of the Controller Board.
Check the Model Setting No. specified on the wiring label. Improper setting may result
in failure or inoperability.
Keep pressing the Set Button, and turn ON the Operation Switch.
Release the Set Button when the Display Window shows “01”.
Press the Ice Button to increase the number, or press the Stop Button to decrease the
47
number until it matches the Model Setting No. on the wiring label.
Press the Set Button again to complete the setting and start icemaking operation in the ICE
mode.
2) Displaying Model Setting No.
Keep pressing the Option Button in the ICE or STOP mode.
The Display Window will show the compressor operating hours ([b] - 3).
Press and release the Ice Button.
The Display Window will show the freeze cycle time ([b] - 9).
When “– –“ appears, press and release the Ice Button.
The Display Window will show the active Model Setting No.
Release the Option Button to return to the original mode.
3) Displaying Compressor Operating Hours
Keep pressing the Option Button in the ICE or STOP mode.
The Display Window will show the compressor operating hours.
“00” indicates the operating hours less than 1,000 hours.
“01” indicates not less than 1,000 hours but less than 2,000 hours.
¦
“25” indicates not less than 25,000 hours but less than 26,000 hours.
4) Resetting Compressor Operating Hours
Do NOT use this command unless necessary.
With the Operation Switch in the OFF position, keep pressing the Ice + Stop + Option
Buttons together, and turn ON the Operation Switch.
Release the Buttons when the Display Window shows the ICE mode.
The Compressor will start 15 seconds after completion of water supply.
The Hot Gas Valve will not open.
The compressor operating hours has been reset.
5) Displaying Error Record
Keep pressing the Option Button in the ICE or STOP mode.
The Display Window will show the compressor operating hours ([b] - 3).
Press and release the Stop Button to display the error record.
A maximum of eight most recent errors will be displayed in reverse order of occurrence,
including those not informed to the user.
“– –“ shows the end of the error record.
Release the Option Button to return to the original mode.
48
6) Displaying Ongoing Error
Keep pressing the Option Button in the ICE or STOP mode.
The Display Window will show the compressor operating hours ([b] - 3).
Press and release the Stop Button to display the error record ([b] - 5).
The most recent errors will be displayed in reverse order of occurrence.
When “– –“ appears, press and release the Stop Button.
The Display Window will show the ongoing error.
Release the Option Button to return to the original mode.
7) Resetting Error Record
Before resetting the errors, record them on the Inspection Record attached to the Front
Panel.
With the Operation Switch in the OFF position, keep pressing the Stop + Option Buttons
together, and turn ON the Operation Switch.
Release the Buttons when the Display Window shows the ICE mode.
The error record has been reset. Do NOT use this command unless necessary.
8) Displaying Gear Motor Errors
Keep pressing the Option Button in the ICE or STOP mode.
The Display Window will show the compressor operating hours ([b] - 3).
Press and release the Stop Button to display the error record ([b] - 5).
The most recent errors will be displayed in reverse order of occurrence.
When “– –“ appears, press and release the Stop Button ([b] - 6).
Press and release the Stop Button to indicate numerals and/or letters six times.
When “– –“ appears, release the Option Button to return to the original mode.
The numerals and/or letters are indicated in hexadecimal notation.
The numerals 0 - 9 are used as 0 - 9, A as 10, b as 11, C as 12, d as 13, E as 14, and F as
15.
In other words, they need conversion to decimal notation by calculating “1st numeral or
letter x 16 + 2nd numeral or letter”.
The converted number presents the frequency of occurrence.
(Example)
Seven Segment Display
00
08
10
36
A1
C0
FF
Frequency of Occurrence in Decimal Notation
0 x 16 + 0 = 0 time
0 x 16 + 8 = 8 times
1 x 16 + 0 = 16 times
3 x 16 + 6 = 54 times
10 x 16 + 1 = 161 times
12 x 16 + 0 = 192 times
15 x 16 + 15 = 255 times
49
The numerals and/or letters will appear in the following order:
1 GM locking detected by current + GM hunting detected by current + (Low GM rotation
speed + High GM current + Voltage above low voltage sensor reset level)
2 GM locking detected by current
3 GM hunting detected by current
4 Low GM rotation speed + High GM current + Voltage above low voltage sensor reset
level
5 Abnormal low voltage
6 Freeze up
9) Displaying Freeze Cycle Time
The five most recent freeze cycles are memorized and will be deleted by turning OFF the
Operation Switch.
Keep pressing the Option Button in the ICE or STOP mode.
The Display Window will show the compressor operating hours ([b] - 3).
Press and release the Ice Button to display the freeze cycle time (max. five cycles).
Release the Option Button to return to the original mode.
The freeze cycle time is displayed with two digits each for minutes [o - E] + [0 - 9] and
seconds [0 - 5] + [0 - 9].
Minutes
[o] + [0 - 9]
[A] + [0 - 9]
[b] + [0 - 9]
[C] + [0 - 9]
[d] + [0 - 9]
[E] + [0 - 9]
=
=
=
=
=
=
0 - 9 min
10 - 19 min
20 - 29 min
30 - 39 min
40 - 49 min
50 - 59 min
Seconds
[0 - 5] + [0 - 9]
(Example)
[o] + [9] [4] + [8] = 9 minutes 48 seconds
[b] + [7] [3] + [6] = 27 minutes 36 seconds
An approximate ice production capacity can be calculated from the freeze cycle time.
With FM-600 or FMN-440,
Ice production capacity (kg/d) = 65,000 / cycle time (sec)
This is just an approximate ice production capacity. The capacity depends on ambient
temperature, water temperature, voltage, and frequency. To determine an accurate
capacity, use a container to receive ice produced for 10 minutes, measure its weight, and
convert it into daily production. Take three measurements, and calculate their average.
50
10) Reducing Compressor Startup Time
With the Operation Switch in the OFF position, keep pressing the Option Button, and turn
ON the Operation Switch.
Release the Option Button when the Display Window shows the ICE mode.
The Compressor will start up about 30 seconds after completion of water supply.
8. PROTECTORS
[a] INDICATION
When an error occurs, “E_” or ”c_”
will appear in the Display Window.
Some of the “c_” errors are not
displayed and must be checked
with error records.
When an operational error occurs, “E_” will appear and blink in the Display Window on the
Operation Board, and the icemaker will stop. When a service call is received, ask the user
to check which error code is in the Display Window. Then, see the error code table in “9.
ERROR CODES” to locate the cause.
[b] PROTECTORS
1) Compressor
Internal Inherent Motor Protector
Senses a temperature rise of the Compressor, and internally shuts off the circuit.
Automatically resets when the temperature goes down. If the Compressor takes a long
time to restart, the Ice Production Timer may shut down the unit with “E1” in the Display
Window. In this case, press the Reset Button.
Internal Pressure Relief Valve
Allows discharge gas into the low side to prevent damage to the Compressor when the
discharge pressure rises excessively. The bypassed gas will trip the above-mentioned
Internal Inherent Motor Protector which will not reset until the temperature goes down.
51
2) Gear Motor
Rotation Sensor
Counts the motor rotation time in every cycle. Controls to reduce the load by flowing hot
gas when the rotation slows down. Shuts down the icemaker when the rotation slows
down further.
Thermal Protector
Provided on the motor coil. Operates when the motor temperature rises. The protector is
auto-reset, but the controller shuts down the icemaker. Press the Reset Button to restart.
Current Sensor
Checks the gear motor current on the Controller Board. Controls to reduce the current by
flowing hot gas when an abnormal current flows. Shuts down the icemaker when the
current rises further.
The above protectors indicate “E3”, “Ed” or “EE”. When “Ed” or “EE” appears ten times,
“EJ” will be displayed. The Evaporator has been frequently overloaded. This could result
in an excessively worn Gear or a broken screw on the Housing.
3) Fan Motor
The auto-reset Fuse attached to the motor coil will operate when the motor temperature
rises. For the air-cooled models, the High Pressure Switch will turn on and off the
icemaker. “E4” may appear in the Display Window.
4) Heater
When the Heater overheats, the auto-reset Bimetal Thermostat will operate at 60°C.
When the Heater overheats further, the Thermal Fuse in the Bimetal Thermostat will burn
out at 98°C. In this case, the Heater requires replacement.
5) Overcurrent Protector
Trips to shut down the icemaker in case of overcurrent conditions.
Manual-reset.
6) Chute Switch
If the Bin Control Switch fails to operate, the Spout and Chute will be clogged with ice and
disconnected to spill ice. The Chute Switch is installed to prevent this trouble. “EL” will
appear in the Display Window when the Chute Switch operates.
7) Low Water
In case of low water or clogged water supply circuit, the icemaker will shut down unless the
52
Float Switch trips at the upper float level within 5 minutes after tripping at the lower float
level. The Water Valve will open and close every 5 minutes until the Float Switch trips at
the upper float level. The record of low water is indicated by the code “c1” when the
Option and Stop Buttons are pressed in servicing.
8) Ice Production Timer
Detects reduction in ice production capacity unless the Float Switch trips at the lower float
level within 30 minutes for the first freeze cycle and 15 minutes for the second and
subsequent cycles after tripping at the upper float level. “E1” will appear in the Display
Window.
9) Water Leak
Detects a water leak if the water level goes down with the Compressor out of operation after
the first water supply cycle (i.e. no ice production). “E0” will appear in the Display Window.
10) Thermistor
The code “Eb” (Condenser Center Thermistor) will blink in the Display Window if the
Thermistor circuit detects infinite resistance (open circuit or bad contact).
11) Float Switch
The Float Switch or connector may have a bad contact if the Float Switch trips at the upper
float level but not at the lower float level with the Flush Water Valve closed. “E2” will
appear in the Display Window.
12) High Pressure Switch
Operates at a high condensing pressure when the air-cooled model has a clogged Air Filter
or a dirty Condenser or the water-cooled model is in a low water condition or has a dirty
heat exchanger inside the Condenser. “E4” will appear in the Display Window when the
Pressure Switch trips five times within an hour.
13) Voltage
If the supply voltage is too low, the Compressor may fail to start properly, or the Gear Motor
may lock to cause freeze-up inside the Evaporator. To prevent these troubles, the
icemaker will shut down and wait until the proper voltage is restored. “EF” will appear in
the Display Window.
53
9. ERROR CODES
Interlock Errors
Code
Error
E0
Icemaking
Water Leak
E1
Low Ice
Production
E2
Float Switch
Error
E3
Gear Motor
Error or Gear
Motor Sensor
Circuit Open
Condition
Following initial water
supply, Float Switch trips at
lower float level after Gear
Motor starts and before
Compressor starts.
Icemaking cycle takes too
long.
With Flush Water Valve
OFF, Float Switch trips at
both upper and lower float
levels for 2 seconds.
Gear Motor is ON with
Rotation Sensor or Current
Sensor circuit open.
Gear Motor Relay is ON
with Gear Motor protective
circuit detector OFF.
Operation
Reset
Check/Repair
Whole unit
stops.
Press Reset
Button.
Water leak, Flush
Water Valve not
closing, Float Switch
Whole unit
stops.
Press Reset
Button.
Gas leak, Control
Water Valve not
closing, Vapor lock,
Freeze up, Float Switch
Whole unit
stops.
Press Reset
Button.
Float Switch
Press Reset
Button.
Rotation Sensor,
Current Sensor
Gear Motor protective
circuit (TPO, Overload,
etc.)
Whole unit
stops.
E4
Abnormal High
Side Pressure
c2 error occurs 5 times in 1
hour of Compressor
operation.
E4 blinks.
N/A
Fan Motor, Cooling
water circuit,
Refrigeration circuit,
Condenser clogged,
Water supply,
Installation conditions
E5
Gear Motor
Drive Element
Error
Gear Motor is OFF on
Controller Board while
Rotation Sensor signals
Gear Motor rotation or
current flows.
Whole unit
stops.
Press Reset
Button.
Miswiring, Gear Motor
Magnet Switch or Relay
Replace Controller
Board.
Discharge Pipe Thermostat
is OFF.
Whole unit
stops.
Press Reset
Button.
Gas leak, Compressor
Cooling Fan failure
Water Temperature
Thermistor circuit is open.
EA blinks.
N/A
Water Temperature
Thermistor
Condenser Center
Thermistor circuit is open.
Eb blinks.
N/A
Condenser Center
Thermistor
Resistor circuit is open.
Whole unit
stops.
Press Reset
Button.
Resistor
Whole unit
stops.
Press Reset
Button.
Gear Motor locked,
hunting or overloaded
Whole unit
stops.
Press Reset
Button.
Gear Motor locked,
hunting, reversing or
overloaded
E8
EA
Eb
EC
Discharge Pipe
Temperature
Error
Water
Temperature
Thermistor
Circuit Open
Condenser
Center
Thermistor
Circuit Open
Resistor Circuit
Open
Ed
Abnormal Gear
Motor Current
EE
Gear Motor
Rotation
Error
Current Sensor detects
locked or hunting Gear
Motor.
Rotation Sensor detects
reversing.
Rotation rate reduces with
current higher than setting
and voltage exceeding low
voltage reset setting.
54
Code
EF
EJ
EL
En
EP
EU
None
Error
Frequent
Voltage Error
Gear Motor
Failure
Precaution
Bin Control
Switch Error
Low Voltage
Sensing
Transformer
Circuit Open
Controller
Board Model
Setting Error
Controller
Board Error
Electric Leak
Short Circuit
Condition
c3 error occurs 3 times in
24 hours.
Operation
Whole unit
stops.
Reset
Press Reset
Button.
Check/Repair
Ed and EE occur 10 times
in total.
EJ blinks.
N/A
Replace Evaporator
and Gear Motor.
Bin Control Protective
Switch trips.
Whole unit
stops.
Press Reset
Button.
Bin Control Switch
Low Voltage Sensing
Transformer circuit is open.
Whole unit
stops.
Press Reset
Button.
Low Voltage Sensing
Transformer
No model setting.
Unacceptable supply
frequency.
Whole unit
stops.
Press Reset
Button.
Model setting
Supply frequency
Controller Board IC fails.
Whole unit
stops.
Replace Controller
Board.
Electric leak or overcurrent.
Whole unit
stops.
Press Reset
Button.
Press Reset
Button.
Replace
Fuse.
Supply voltage
Electric leak, Fuse
Non-Interlock Errors
Code
Error
CM Microcomputer
Time Read/Write
“— —” Error
c1
c2
c3
Low Water
Condition
Operation
Reset
Microcomputer fails to
read/write properly.
Memory circuit
not available.
Replace
Controller
Board.
Water supply continues
for more than 90
seconds, or Float Switch
trips at lower float level
and does not reset for
more than 60 seconds
after water supply.
Whole unit stops
until Reservoir
fills up. Only
Control Water
Valve operates
intermittently for 5
minutes.
Automatically
resets after
Reservoir fills
up.
Abnormal High
Side Pressure
Pressure Switch stays
OFF for 5 seconds.
Whole unit stops.
Abnormal Low
Voltage
Voltage stays below
setting for more than 1
second with Compressor
ON and Control Water
Valve OFF.
c3 blinks.
c4
Drain Error
c5
Gear Motor
Error
Float Switch trips at
upper float level in 10
Indication only.
minutes after Flush Water
Valve turns ON.
Whole unit stops
Rotation rate reduces.
except Control
Water Valve.
55
Automatically
resets after
Pressure
Switch turns
ON.
Automatically
resets after
voltage stays
above reset
setting for 2
minutes.
Check/Repair
Error records and
compressor
operating hours not
available on display
Water supply
interruption, Control
Water Valve not
opening, Flush
Water Valve not
closing, Float
Switch, Water leak
Condenser
clogged, Cooling
water circuit,
Refrigeration circuit
Supply voltage
N/A
Flush Water Valve
not opening,
Control Water Valve
not closing
Automatically
resets after 2
minutes.
Gear Motor
overloaded
10. PERFORMANCE DATA
22
1.8
Head Pressure
(bar)
20
1.6
Head Pressure(bar)
Suction Pressure
(bar)
18
1.4
16
1.2
14
1
12
0.8
10
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
800
Ice Production Capacity(kg/day)
700
600
500
400
300
Ice Production
Capacity(kg/day)
+10%
200
-10%
100
0
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
Water consumption(m3/day)
1
0.8
0.6
0.4
0.2
0
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
56
0.6
Suction Pressure(bar)
[a] FM-600AHE
22
20
1.8
Head Pressure
(bar)
1.6
Head Pressure(bar)
Suction Pressure
(bar)
18
1.4
16
1.2
14
1
12
0.8
10
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
800
600
500
400
300
Ice Production
Capacity(kg/day)
+10%
200
-10%
100
0
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
5
Water consumption(m3/day)
Ice Production Capacity(kg/day)
700
4
3
2
1
0
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
57
0.6
Suction Pressure(bar)
[b] FM-600AWHE
[c] FMN-440AHE
Head Pressure(bar)
22
20
2
Head Pressure
( bar )
Suction Pressure
( bar )
1.4
16
1.2
14
1
0.8
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
800
700
Ice Production Capacity(kg/day
1.6
18
12
600
500
400
300
200
Ice Production
Capacity(kg/day)
+10%
100
-10%
0
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
1
Water consumption(m3/day)
1.8
0.8
0.6
0.4
0.2
0
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
58
Suction Pressure(bar)
24
24
Head Pressure(bar)
22
20
2
Head Pressure
( bar )
Suction Pressure
( bar )
1.4
16
1.2
14
1
0.8
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
800
700
Ice Production Capacity(kg/day
1.6
18
12
600
500
400
300
200
100
Ice Production
Capacity(kg/day)
+10%
-10%
0
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
5
4
Water consumption(m3/day)
1.8
3
2
1
0
10/10 21/15 32/21
Ambient Temp/Water Temp(°C)
59
Suction Pressure(bar)
[d] FMN-440AWHE
IV. SERVICE DIAGNOSIS
Display error record by operating the Operation Board (See “III. 7. [b] 5) Displaying Error
Record”). Check for a possible cause and service the unit.
1. NO ICE PRODUCTION
PROBLEM
[1] The icemaker
will not start.
POSSIBLE CAUSE
a) Power Supply
1. OFF position.
2. Loose connections.
3. Bad contacts.
b) Fuse (Controller
Board)
4. Blown fuse.
5. Voltage too low.
1. Blown out. No
indication on
Operation Board.
c) Transformer
Receptacle
d) Operation Switch
1. Disconnected.
e) Transformer
f) Water Valve
g) Water Supply Tap
1. Coil winding opened.
1. Coil winding opened.
1. Closed.
2. Water failure.
1. Disconnected.
2. Terminal out of Plug
or Receptacle.
1. Tripped.
h) Plug and
Receptacle
(Control Box)
i) Chute Switch
1. OFF position.
2. Bad contacts.
j) Overload Protector 1. Tripped.
k) Model Setting No. 1. Incorrect.
[2] Water does not
stop, and the
icemaker will not
start.
a) Water Control
Relay (Controller
Board)
b) Float Switch
c) Flush Water Valve
[3] Water has been
supplied, but the
icemaker will not
start.
d) Hoses
e) Mechanical Seal
f) Reservoir
a) Bin Control
1. Contacts fused.
2. Coil winding opened.
1. Bad contacts.
2. Float does not move
freely.
1. Valve seat clogged
and water leaking.
1. Disconnected.
1. Water leaks.
1. Cracked.
1. Bad contacts.
2. Activator does not
move freely.
60
REMEDY
1. Move to ON position.
2. Tighten.
3. Check for continuity and
replace.
4. Replace.
5. Get recommended voltage.
1. Find out the cause of short
circuit (ex. Control Water
Valve, Flush Water Valve),
resolve it, and replace
Controller Board.
1. Connect.
1. Move to ON position.
2. Check for continuity and
replace.
1. Replace.
1. Replace.
1. Open.
2. Wait till water is supplied.
1. Connect.
2. Insert Terminal back in
position.
1. See “III. 6. [i] CHUTE
SWITCH”.
2. Reset.
2. Set correct No. See “III. 7.
[b] 1) Setting Model No.”
1. Replace Controller Board.
2. Replace Controller Board.
1. Check for continuity and
replace.
2. Clean or replace.
1. Clean or replace.
1. Connect.
1. Replace.
1. Replace.
1. Check for continuity and
replace.
2. Clean Axle and its
corresponding holes or
replace Bin Control. See “III.
6. [h] BIN CONTROL
SWITCH”.
PROBLEM
[3] (Continued)
POSSIBLE CAUSE
b) Gear Motor
1. Tripped.
Protector
(Thermal
Breaker)
c) Controller Board
1. Broken.
d) Pressure Switch 1. Dirty Condenser fins.
2. Ambient temperature
too warm.
3. Fan not rotating.
4. Condenser water
pressure too low or
off.
5. Water Regulating
Valve clogged.
6. Refrigerant
overcharged.
7. Refrigerant line or
components plugged.
8. Bad contacts.
e) Thermostat
(Water-cooled
Model)
9. Loose connections.
1. Ambient temperature
too warm.
2. Hot Gas Valve not
closing.
3. Hot Gas Valve open.
4. Compressor Cooling
Fan Motor defective.
5. Bad contacts.
[4] Gear Motor
starts, but
Compressor will
not start or
operates
intermittently.
a) X1 and X2
Relays
b) Compressor
c) Power Supply
[5] Gear Motor and
Compressor
start, but no ice
is produced.
d) Controller Board
a) Refrigerant Line
6. Loose connections.
1. Bad contacts.
2. Coil winding opened.
1. Loose connections.
2. Motor winding opened
or earthed.
3. Motor Protector
tripped.
1. Circuit Ampacity too
low.
1. Broken.
1. Gas leaks.
2. Refrigerant line
clogged.
61
REMEDY
1. Find out the cause, resolve it,
and press Reset Button on
Motor Protector.
1. Replace.
1. Clean.
2. Check for recommended
temperature.
3. See 3 - [1] - a).
4. Check and get recommended
pressure.
5. Clean.
6. Recharge.
7. Clean and replace Drier.
8. Check for continuity and
replace.
9. Tighten.
1. Check for recommended
temperature.
2. Replace.
3. Remove the cause of Gear
Motor overload. (Hot Gas
Valve opens when Gear Motor
is overloaded.)
4. Replace.
5. Check for continuity and
replace.
6. Tighten.
1. Check for continuity and
replace Controller Board.
2. Replace Controller Board.
1. Tighten.
2. Replace.
3. Find out the cause of overheat
or overcurrent.
1. Install a larger-sized
conductor.
1. Replace
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. Replace the clogged
component.
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
1. Dirty Air Filter or
Pressure Too
Condenser.
High
2. Ambient or condenser
water temperature too
warm.
3. Condenser water
pressure too low or
off.
4. Fan rotating too slow.
5. Water Regulating
Valve clogged.
c) Expansion Valve 1. Low-side pressure
(not adjustable)
exceeding the limit.
d) Evaporator
1. Evaporator pipe
crushed.
e) Hot Gas Valve
1. Open.
REMEDY
1. See 1 - [5] - a).
2. Replace the clogged
component.
3. Recharge.
1. Clean.
2. Check for recommended
temperature.
3. Check and get recommended
pressure.
4. See 3 - [1] - a).
5. Clean.
1. Replace.
1. Replace.
1. At startup and in case of Gear
Motor overload, hot gas flows
and ice production reduces.
Remove the cause of Gear
Motor overload.
3. OTHERS
PROBLEM
[1] Abnormal noise
POSSIBLE CAUSE
a) Fan Motor
1. Bearing worn out.
(Condenser Unit) 2. Fan blade deformed.
3. Fan blade does not
move freely.
b) Compressor
1. Bearings worn out, or
cylinder valve broken.
2. Mounting pad out of
position.
c) Refrigerant Lines 1. Rub or touch lines or
other surfaces.
d) Gear Motor (Ice
1. Bearing or Gear
Making)
wear/damage.
e) Evaporator
1. Low-side pressure too
low.
REMEDY
1. Replace.
2. Replace fan blade.
3. Replace.
1. Replace.
2. Reinstall.
1. Replace.
1. Replace.
1. See if Expansion Valve Bulb is
mounted properly, and
replace the valve if necessary.
2. Scale on inside wall of 2. Remove Auger. Use a
Freezing Cylinder.
solution of lime removing
cleaner to clean periodically.
If water is found to surpass
the following levels, install a
conditioner.
Hardness 50 ppm
Silica 30 ppm
62
PROBLEM
[1] (Continued)
[2] Overflow from
Reservoir (Water
does not stop.)
[3] Gear Motor
Protector
operates
frequently.
POSSIBLE CAUSE
f) Heater
1. Broken.
g) CPR (Condenser 1. Internal leaks.
Unit)
a) Water Supply
1. Water pressure too
high.
b) Water Valve
1. Diaphragm does not
close.
c) Float Switch
1. Bad contacts.
a) Power Supply
Voltage
b) Evaporator Assy
1. Too high or too low.
1. Bearings or Auger
worn out.
63
REMEDY
1. Replace.
1. Replace.
1. Install a Pressure Reducing
Valve.
1. Clean or replace.
1. Check for continuity and
replace.
1. Connect the unit to a power
supply of proper voltage.
1. Replace Bearing or Auger.
V. REMOVAL AND REPLACEMENT OF COMPONENTS
1. SERVICE FOR REFRIGERANT LINES
[a] SERVICE INFORMATION
1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R404A]
The compressor must not be opened more than 30 minutes in replacement or service. Do
not mix lubricants of different compressors even if both are charged with the same refrigerant,
except when they use the same lubricant.
2) Treatment for Refrigerant Leak [R404A]
If a refrigerant leak occurs in the low side of an ice maker, air may be drawn in. Even if the low
side pressure is higher than the atmospheric pressure in normal operation, a continuous
refrigerant leak will eventually lower the low side pressure below the atmospheric pressure
and will cause air suction. Air contains a large amount of moisture, and ester oil easily absorbs
a lot of moisture. If an ice maker charged with R404A has possibly drawn in air, the drier
must be replaced. Be sure to use a drier designed for R404A.
3) Handling of Handy Flux [R404A]
Repair of the refrigerant circuit needs brazing. It is no problem to use the same handy flux
that has been used for the current refrigerants. However, its entrance into the refrigerant
circuit should be avoided as much as possible.
4) Oil for Processing of Copper Tubing [R404A]
When processing the copper tubing for service, wipe off oil, if any used, by using alcohol or
the like. Do not use too much oil or let it into the tubing, as wax contained in the oil will clog the
capillary tubing.
5) Service Parts for R404A
Some parts used for refrigerants other than R404A are similar to those for R404A. But never
use any parts unless they are specified for R404A because their endurance against the
refrigerant have not been evaluated. Also, for R404A, do not use any parts that have been
used for other refrigerants. Otherwise, wax and chlorine remaining on the parts may adversely
affect R404A.
6) Replacement Copper Tubing [R404A]
The copper tubes currently in use are suitable for R404A. But do not use them if oily inside.
The residual oil in copper tubes should be as little as possible. (Low residual oil type copper
tubes are used in the shipped units.)
64
7) Evacuation, Vacuum Pump and Refrigerant Charge [R404A]
Never allow the oil in the vacuum pump to flow backward. The vacuum level and vacuum
pump may be the same as those for the current refrigerants. However, the rubber hose and
gauge manifold to be used for evacuation and refrigerant charge should be exclusively for
R404A.
8) Refrigerant Leak Check
Refrigerant leaks can be detected by charging the unit with a little refrigerant, raising the
pressure with nitrogen and using an electronic detector. Do not use air or oxygen instead of
nitrogen for this purpose, or rise in pressure as well as in temperature may cause R404A to
suddenly react with oxygen and explode. Be sure to use nitrogen to prevent explosion.
[b] REFRIGERANT RECOVERY
The refrigerant must be recovered if required by an applicable law. A Low-side Access
Valve is provided in the unit. Recover the refrigerant from the Access Valve, and store it in a
proper container. Do not discharge the refrigerant into the atmosphere.
When replacing the Drier, take the opportunity to also fit a High-side Access Valve for ease
of charging liquid refrigerant.
[c] EVACUATION AND RECHARGE
1) Attach Charging Hoses, Service Manifold and Vacuum Pump to the Low-side and Highside (to be fitted by servicer) Access Valves. If possible, use Quick Release Connectors
onto the Access Valves (especially on the high side).
2) Turn on the Vacuum Pump.
3) Allow the Vacuum Pump to pull down to a 760 mmHg vacuum. Evacuating period depends
on the pump capacity.
4) Close the Low-side and High-side Valves on the Service Manifold.
5) Disconnect the Vacuum Pump, and attach a Refrigerant Charging Cylinder to accurately
weigh in the liquid charge. Remember to purge any air from the Charging Hose. See the
Nameplate for the required refrigerant charge.
6) Open the High-side Valve on the Gauge Manifold, and accurately measure in the liquid
charge. Close the valve on the Charging Cylinder before closing the High-side Manifold
Valve. Any remaining liquid in the line can be charged into the low side.
Note: Always charge in the liquid stage, as many refrigerants are blends and vapour
charging will affect the blend consistency (eg. R404A).
65
7) Turn on the icemaker. Release the High-side Access Connector, and allow pressure in
the charging line to slowly enter the low side of the system. Cap off the High-side Access
Valve. When pressure reduces on the low side, disconnect the low side charging line
and cap off the Access Valve.
8) Always cap the Access Valves to prevent a refrigerant leak. Tighten the cap to a torque of
9.81 - 12.26 Nm.
9) Always thoroughly leak test all joints and valve caps.
10) Avoid charging large quantities of liquid into the low side in case of damage to the
Compressor.
Depressed
Cap
Access Valve
OPEN
Fig. 13
2. BRAZING
DANGER
1. Refrigerant R404A itself is not flammable, explosive and poisonous. However,
when exposed to an open flame, R404A creates Phosgene gas, hazardous
in large amounts.
2. Always recover the refrigerant and store it in a proper container, if required
by an applicable law. Do not discharge the refrigerant into the atmosphere.
3. Do not use silver alloy or copper alloy containing Arsenic.
4. In its liquid state, the refrigerant can cause frostbite because of the low
temperature.
66
3. COMPRESSOR
IMPORTANT
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) Disconnect the power source.
2) Remove the panels.
3) Remove the Terminal Cover on the Compressor, and disconnect the Compressor wiring.
4) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See “1. [b] REFRIGERANT RECOVERY”).
5) Remove the Discharge, Suction and Access Pipes from the Compressor using brazing
equipment.
WARNING
When repairing a refrigerant system, be careful not to let the burner flame contact
any electrical wires or insulation.
6) Remove the Bolts and Rubber Grommets.
7) Slide and remove the Compressor. Unpack the new Compressor package. Install the
new Compressor.
8) Attach the Rubber Grommets of the previous Compressor.
9) Clean the Suction and Discharge Pipes with an abrasive cloth/paper.
10) Place the Compressor in position, and secure it using the Bolts and Washers.
11) Remove plugs from the Discharge, Suction and Access Pipes.
12) Braze the Access, Suction and Discharge Pipes (Do not change this order) with nitrogen
gas flowing at the pressure of 0.2 - 0.3 bar.
13) Install the new Drier (See "4. DRIER").
14) Check for leaks using nitrogen gas (10 bar) and soap bubbles.
67
15) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required
refrigerant charge (See “1. [c] EVACUATION AND RECHARGE”).
16) Connect the Terminals to the Compressor, and replace the Terminal Cover in its correct
position.
17) Refit the panels in their correct position.
18) Connect the power source.
4. DRIER
IMPORTANT
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) Disconnect the power source.
2) Remove the Front Panel.
3) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See “1. [b] REFRIGERANT RECOVERY”).
4) Remove the Drier using brazing equipment.
5) Install the new Drier with the arrow on the Drier in the direction of the refrigerant flow. Use
nitrogen gas at the pressure of 0.2 - 0.3 bar when brazing the tubings.
6) Check for leaks using nitrogen gas (10 bar) and soap bubbles.
7) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required
refrigerant charge (See “1. [c] EVACUATION AND RECHARGE”).
8) Refit the Front Panel in its correct position.
9) Connect the power source.
68
5. 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 repair or replacement has been made.
1) Disconnect the power source.
2) Remove the Front Panel.
3) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See “1. [b] REFRIGERANT RECOVERY”).
4) Remove the Expansion Valve Bulb at the Evaporator outlet.
5) Remove the Expansion Valve Cover, and disconnect the Expansion Valve using brazing
equipment.
6) Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar.
WARNING
Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 120°C.
7) Install the new Drier (See "4. DRIER").
8) Check for leaks using nitrogen gas (10 bar) and soap bubbles.
9) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required
refrigerant charge (See "1. [c] EVACUATION AND RECHARGE").
10) Attach the Bulb to the suction line. Be sure to secure the Bulb using a wire or clamp and
replace the insulation.
11) Place the new set of Expansion Valve Covers in position.
12) Refit the Front Panel in its correct position.
13) Connect the power source.
69
6. 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 repair or replacement has been
made.
1) Unplug the icemaker.
2) Close the water supply tap.
3) Remove the panels.
4) Recover the refrigerant and store it in a proper container, if required by an applicable law.
5) Disconnect the Capillary Tube using brazing equipment.
6) Disconnect the Flare-connections of the valve.
7) Remove the screws and the valve from the Bracket.
8) Install the new valve, and braze the Capillary Tube.
9) Install the new Drier.
10) Check for leaks using nitrogen gas (10 bar) and soap bubbles.
11) Connect the Flare-connections.
12) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required
refrigerant charge.
13) Open the water supply tap.
14) Plug in the icemaker.
15) Check for water leaks.
16) See “III. 5. [k] WATER REGULATOR”. If necessary, adjust the valve.
17) Replace the panels in position.
70
7. EVAPORATOR ASSEMBLY
1) Push the Stop Button to drain the water in the Evaporator.
2) Disconnect the power source.
3) Remove the panels.
4) Remove the Band connecting the Spout with the Chute Assembly.
5) Remove the three Thumbscrews, and take off the Spout from the Evaporator.
CUTTER
6) Remove the Bolt and lift off the Cutter.
7) Remove the Rubber O-ring and the Nylon Ring at the top of the Evaporator.
BELT HEATER
8) Detach the spring, and remove the Belt Heater.
EXTRUDING HEAD
9) Remove the three Socket Head Cap Screws, and lift off the Extruding Head.
10) Check the Bearing inside the Extruding Head. If it is worn out or scratched, replace the
Bearing.
Note: Replacing the Bearing needs a fitting tool. If it is not available, replace the whole
Extruding Head.
AUGER
11) Lift out the Auger. Check the top and bottom areas in contact with the Bearings. If the
surface is scratched or pitted, replace the Auger. Check the blade edge of the Auger. If
it is scratched or worn where it has contacted the Evaporator, replace it.
EVAPORATOR
Note: Skip the following steps 12) through 14) when the Evaporator does not need
replacement.
71
12) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See "1. [b] REFRIGERANT RECOVERY").
IMPORTANT
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.
13) Remove the Bulb of the Expansion Valve.
14) Disconnect the brazing connections of the Expansion Valve and the Copper Tube - Low
Side from the Evaporator, using brazing equipment.
WARNING
Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 120°C.
15) Remove the two Truss Head Machine Screws and the Strap securing the Evaporator.
16) Disconnect the three Hoses from the Evaporator.
17) Remove the four Socket Head Cap Screws securing the Evaporator with the Bearing Lower.
18) Lift off the Evaporator.
BEARING - LOWER AND MECHANICAL SEAL
19) The Mechanical Seal consists of two parts. One part rotates with the Auger, the other is
static and is fitted into a top recess in the Housing. If the contact surfaces of these two
parts become worn or scratched, the Mechanical Seal may leak water and should be
replaced.
20) Remove the O-ring on the top outer edge of the Housing.
21) Remove the four Bolts and lift the Housing clear of the Gear Motor. Check the Bearing
inside the Housing. If it is worn or scratched, replace it using a fitting tool. Carefully ease
out the lower part of the Mechanical Seal before replacing the Bearing.
Note: If a fitting tool is not available, replace the whole Lower Housing complete with
Bearing.
72
GEAR MOTOR
22) Cut the Connectors.
23) Remove the three Socket Head Cap Screws securing the Gear Motor.
24) Assemble the removed parts in the reverse order of which they were removed.
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.
25) When replacing the Evaporator;
(a) Braze the new Evaporator with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar.
(b) Replace the Drier.
(c) Check for leaks using nitrogen gas (10 bar) and soap bubbles.
(d) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required
refrigerant charge (See "1. [c] EVACUATION AND RECHARGE").
26) Refit the panels in their correct position.
27) Connect the power source.
73
74
8. CONTROL WATER VALVE
1) Disconnect the power source.
2) Close the water supply tap.
3) Remove the panels.
4) Disconnect the Terminals from the Control Water Valve.
5) Remove the Cover - Reservoir Inlet from the Control Water Valve.
6) Loosen the Fitting Nut on the Control Water Valve Inlets, and remove the Control Water
Valve. Do not lose the Packings inside the Fitting Nut.
7) Install the new Control Water Valve.
8) Assemble the removed parts in the reverse order of which they were removed.
9) Open the water supply tap.
10) Connect the power source.
11) Check for water leaks.
12) Refit the panels in their correct position.
75
9. FLUSH WATER VALVE
1) Close the water supply tap.
2) Remove the panels.
3) Push the Stop Button, and after 5 minutes disconnect the power source.
4) 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.
5) Disconnect the Terminals from the Flush Water Valve.
6) Remove the Flush Water Valve from the Bracket.
7) Remove the Drain Pipe from the Flush Water Valve.
8) Connect the Drain Pipe to the new Flush Water Valve, and place the valve in position.
9) Connect the Hose to the Flush Water Valve, and secure it with the Clamp.
10) Pour water into the Reservoir, and check for water leaks on the Flush Water Valve.
11) Open the water supply tap.
12) Connect the power source.
13) Check for water leaks.
14) Push the Stop Button, and make sure water is flushing.
15) Push the Ice Button.
16) Refit the panels in their correct position.
76
10. CONTROLLER BOARD
IMPORTANT
A single type Controller Board is supplied as a Service Board. Some
modifications and adjustment will be required to fit the icemaker models. Do
not repair any parts and electronic devices on the Controller Board in the field.
Replace the whole board with a new Service Board.
[a] MODIFICATION
1) Check that the Service Board package includes:
Controller Board
Instruction Sheet
1 pc.
1 pc.
2) Modify the Service Board referring to the Instruction Sheet attached (Set the Model Setting
No. according to "III. 7. [b] 1) Setting Model No.").
[b] REPLACEMENT
1) Disconnect the power source.
2) Remove the Front Panel.
3) Remove screws and the Control Box Cover.
4) Disconnect the Connectors and Board Support from the Controller Board.
5) Remove the Controller Board from the Control Box.
6) Install the new Controller Board and reassemble the Control Box in the reverse order of
the removal procedure.
7) Replace the Front Panel in its correct position.
8) Connect the power source.
77
11. HOT GAS VALVE
IMPORTANT
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) Disconnect the power source.
2) Remove the panels.
3) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See “1. [b] REFRIGERANT RECOVERY”).
4) Remove the Hot Gas Valve using brazing equipment.
5) Unscrew the coil of the new Hot Gas Valve.
6) Braze the new Hot Gas Valve with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar.
WARNING
Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 120°C.
7) Install the new Drier (See "4. DRIER").
8) Check for leaks using nitrogen gas (10 bar) and soap bubbles.
9) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required
refrigerant charge (See "1. [c] EVACUATION AND RECHARGE").
10) Screw down the coil.
11) Refit the panels in their correct position.
12) Connect the power source.
78
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