Hoshizaki FM-170AFE-N Service manual

NO. E2GA-734

ISSUED: MAY 18, 2007

REVISED: APR. 18, 2011

HOSHIZAKI

MODULAR ICE MAKER

MODEL

FM-170AFE

SERVICE MANUAL

CONTENTS

PAGE

I. SPECIFICATIONS -------------------------------------------------------------------------------------1

1. DIMENSIONS/CONNECTIONS ----------------------------------------------------------------1

[a] FM-170AFE(-N) ---------------------------------------------------------------------------------1

[b] WITH STORAGE BIN (B-300PG) ----------------------------------------------------------2

2. SPECIFICATIONS ----------------------------------------------------------------------------------3

[a] FM-170AFE --------------------------------------------------------------------------------------3

[b] FM-170AFE-N -----------------------------------------------------------------------------------4

II. GENERAL INFORMATION -------------------------------------------------------------------------5

1. CONSTRUCTION ----------------------------------------------------------------------------------5

2. OPERATION - How it works ---------------------------------------------------------------------7

3. TIMER BOARD --------------------------------------------------------------------------------------8

[a] SOLID-STATE CONTROL -------------------------------------------------------------------8

[b] TIMER BOARD ---------------------------------------------------------------------------------8

[c] SEQUENCE -------------------------------------------------------------------------------------9

III. MAINTENANCE AND CLEANING INSTRUCTIONS -------------------------------------- 12

1. EXTRUDING HEAD (UPPER BEARING), HOUSING (LOWER BEARING) ----- 12

2. MECHANICAL SEAL --------------------------------------------------------------------------- 12

3. GEAR MOTOR ---------------------------------------------------------------------------------- 13

4. CONDENSER ------------------------------------------------------------------------------------ 13

5. AIR FILTER --------------------------------------------------------------------------------------- 13

6. WATER VALVE ---------------------------------------------------------------------------------- 14

7. CLEANING OF WATER SYSTEM ---------------------------------------------------------- 15

8. PERIODICAL CLEANING --------------------------------------------------------------------- 17

IV. TECHNICAL INFORMATION -------------------------------------------------------------------- 18

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT --------------------------------------- 18

2. CONTROL BOX ----------------------------------------------------------------------------------- 19

3. WIRING DIAGRAM ------------------------------------------------------------------------------ 20

4. TIMING CHART ----------------------------------------------------------------------------------- 21

[a] PRINCIPLE OF OPERATION ------------------------------------------------------------- 21

[b] PROTECTORS ------------------------------------------------------------------------------- 21

5. PERFORMANCE DATA ------------------------------------------------------------------------- 23

[a] FM-170AFE ------------------------------------------------------------------------------------ 23

[b] FM-170AFE-N --------------------------------------------------------------------------------- 24

V. SERVICE DIAGNOSIS ---------------------------------------------------------------------------- 25

1. NO ICE PRODUCTION ------------------------------------------------------------------------- 25

2. LOW ICE PRODUCTION ----------------------------------------------------------------------- 27

3. OTHERS -------------------------------------------------------------------------------------------- 27

VI. REMOVAL AND REPLACEMENT OF COMPONENTS ---------------------------------- 29

1. SERVICE FOR REFRIGERANT LINES ---------------------------------------------------- 29

[a] SERVICE INFORMATION ----------------------------------------------------------------- 29 i

[b] REFRIGERANT RECOVERY ------------------------------------------------------------- 30

[c] EVACUATION AND RECHARGE -------------------------------------------------------- 30

2. BRAZING ------------------------------------------------------------------------------------------- 31

3. COMPRESSOR ----------------------------------------------------------------------------------- 31

4. DRIER ----------------------------------------------------------------------------------------------- 33

5. EXPANSION VALVE ----------------------------------------------------------------------------- 34

6. EVAPORATOR ASSEMBLY ------------------------------------------------------------------- 35

7. FAN MOTOR --------------------------------------------------------------------------------------- 39

8. FLOAT SWITCH ---------------------------------------------------------------------------------- 39

9. CONTROL WATER VALVE -------------------------------------------------------------------- 40 ii

I. SPECIFICATIONS

1. DIMENSIONS/CONNECTIONS

[a] FM-170AFE(-N)

1

[b] WITH STORAGE BIN (B-300PG)

2

2. SPECIFICATIONS

[a] FM-170AFE

AC SUPPLY VOLTAGE

AMPERAGE

STARTING AMPERAGE

ELECTRIC CONSUMPTION

POWER FACTOR

POWER SUPPLY CAPACITY

1 phase 220-240V 50Hz 220-230V 60Hz

4.1A (Ambient temp. 32°C, Water temp. 21°C)

19.0A

620W (Ambient temp. 32°C, Water temp. 21°C)

66%

1.24kVA

ICE PRODUCTION PER 24h Approx. 170 kg (Ambient temp. 10°C, Water temp. 10°C)

Approx. 145 kg (Ambient temp. 21°C, Water temp. 15°C)


WATER CONSUMPTION PER 24h Approx. 0.17 m

3

(Ambient temp. 10°C, Water temp. 10°C) m

3

(Ambient temp. 32°C, Water temp. 21°C)

SHAPE OF ICE

MAX STORAGE CAPACITY

DIMENSIONS (DRAWING No.)

EXTERIOR

INSULATION

CONNECTION - ELECTRIC

- WATER SUPPLY

- DRAIN

ICE MAKING SYSTEM

HARVESTING SYSTEM

COMPRESSOR

CONDENSER

EVAPORATOR

REFRIGERANT CONTROL

REFRIGERANT CHARGE

Flake

Not applicable

560(W) x 700(D) x 780(H) (mm)

Stainless Steel, Galvanized Steel (Rear)

Polyurethane Foam

Z-type Con.

Inlet

Outlet

G 3/4”

R 3/4”

(Connected at rear)

(Connected at rear)

Auger type

Direct driven Auger (80W Gear Motor)

Hermetic Compressor 495W Model SC18G

Fin and Tube type forced air cooling

Copper Tube on Cylinder

Thermostatic Expansion Valve

R134a 390g

BIN CONTROL SYSTEM

ICE MAKING WATER CONTROL

ELECTRICAL PROTECTION

COMPRESSOR PROTECTION

GEAR MOTOR PROTECTION

LOW WATER PROTECTION

BIN CONTROL PROTECTION

WEIGHT

PACKAGE

Mechanical Bin Control (Time Delay Controlled)

Float Switch and Water Valve

Class I Appliance

6A Circuit Breaker

Auto-reset Overload Protector

Auto-reset Pressure Switch

Manual-reset Circuit Breaker

Auto-reset Thermal Protector

Float Switch and Timer

Mechanical Switch

Net weight 75kg / Gross weight 87kg

Carton 671mm(W) x 820mm(D) x 900mm(H)

ACCESSORIES

OPERATION CONDITIONS

AMBIENT TEMP.

WATER SUPPLY TEMP

WATER SUPPLY PRESSURE

Scoop, Installation Kit

5 - 40°C

5 - 35°C

0.5 - 8 bar (0.05 - 0.8MPa)

We reserve the right to make changes in specifications and design without prior notice.

3

[b] FM-170AFE-N

AC SUPPLY VOLTAGE

AMPERAGE

STARTING AMPERAGE

ELECTRIC CONSUMPTION

POWER FACTOR

POWER SUPPLY CAPACITY

1 phase 220-240V 50Hz 220-230V 60Hz

4.1A

19.0A

640W

68%

1.24kVA



ICE PRODUCTION PER 24h Approx.

Approx.

160 kg (Ambient temp. 10°C, Water temp. 10°C)

135 kg (Ambient temp. 21°C, Water temp. 15°C)


WATER CONSUMPTION PER 24h Approx. 0.16 m

3

(Ambient temp. 10°C, Water temp. 10°C) m

3


SHAPE OF ICE

MAX STORAGE CAPACITY

DIMENSIONS (DRAWING No.)

EXTERIOR

INSULATION

CONNECTION - ELECTRIC

- WATER SUPPLY

- DRAIN

ICE MAKING SYSTEM

HARVESTING SYSTEM

COMPRESSOR

CONDENSER

EVAPORATOR

REFRIGERANT CONTROL

REFRIGERANT CHARGE

BIN CONTROL SYSTEM

ICE MAKING WATER CONTROL

ELECTRICAL PROTECTION

COMPRESSOR PROTECTION

GEAR MOTOR PROTECTION

LOW WATER PROTECTION

BIN CONTROL PROTECTION

WEIGHT

PACKAGE

ACCESSORIES

OPERATION CONDITIONS

AMBIENT TEMP.

WATER SUPPLY TEMP

WATER SUPPLY PRESSURE

Nugget

Not applicable

560(W) x 700(D) x 780(H) (mm)

Stainless Steel, Galvanized Steel (Rear)

Polyurethane Foam

Z-type Con.

Inlet G 3/4”

Outlet R 3/4”

Auger type

(Connected at rear)

(Connected at rear)

Direct driven Auger (80W Gear Motor)

Hermetic Compressor 495W Model SC18G

Fin and Tube type forced air cooling

Copper Tube on Cylinder

Thermostatic Expansion Valve

R134a 390g

Mechanical Bin Control (Time Delay Controlled)

Float Switch and Water Valve

Class I Appliance

6A Circuit Breaker

Auto-reset Overload Protector

Auto-reset Pressure Switch

Manual-reset Circuit Breaker

Auto-reset Thermal Protector

Float Switch and Timer

Mechanical Switch

Net weight 75kg / Gross weight 87kg

Carton 671mm(W) x 820mm(D) x 900mm(H)

Scoop, Installation Kit

5 - 40°C

5 - 35°C

0.5 - 8 bar (0.05 - 0.8MPa)

We reserve the right to make changes in specifications and design without prior notice.

4

II. GENERAL INFORMATION

1. CONSTRUCTION

Modular flaker models FM-170AFE and FM-170AFE-N include Water Supply,

Evaporator, Compressor, Condenser and Control Assemblies. As the unit is not equipped with an Ice Storage Bin, this must be purchased separately as an optional extra.

Water Valve

Reservoir

Drier

Ice Chute

Control Box

Evaporator

Gear Motor

Fan Motor

Compressor

5

ICE MAKING UNIT

6

2. OPERATION - How it works

Potable water flows from the external supply tap and enters the water inlet on the machine, passes through an electrically operated Water Valve before flowing into the

Reservoir Tank. From the Tank, water flows by gravity into the bottom of the Evaporator to completely surround the Auger and fill the Evaporator with water to the same level as in the Reservoir Tank.

Water leakage at the bottom of the Evaporator is prevented by the use of a mechanical seal.

The Evaporator serves to change the water into ice by using a heat exchange process in conjunction with the Compressor/Condenser assembly.

As water is used and turned into ice, the level in the Evaporator and the Reservoir Tank will fall. At a pre-determined level, a dual action Float Switch fitted to the Reservoir Tank electrically commands the Water Valve to open and refill the Tank. This system functions therefore to maintain a constant water level inside the Evaporator assembly.

The Auger, which is located inside the Evaporator is driven by an external Gear Motor assembly. The rotating Auger carries the ice upwards where it is pressed against the

Extruding Head at the top of the Evaporator to remove excess water, before finally being extruded and broken into irregular shapes and sizes of ice by the Flake/Nugget Cutter or into cubelet ice.

The continuous flow of ice is then pushed into the Ice Spout and falls by gravity into the

Storage Bin below.

Moving the Operation Switch, located on the Control Box, to the “ON” position starts an automatic and continuous icemaking process. When the Storage Bin has filled with ice, the Bin Control Switch, located at the top of the Storage Bin, stops the icemaking process. When ice is removed from the Storage Bin, the Bin Control Switch will automatically reset and restart the icemaking process.

7

3. TIMER BOARD

[a] SOLID-STATE CONTROL

1) An exclusive HOSHIZAKI solid-state control is employed in FM-170AFE and FM-

170AFE-N modular icemakers.

2) A Printed Circuit Board (hereafter called “Timer Board”) includes a stable and highquality control system.

3) No adjustment is required.

[b] TIMER BOARD

CAUTION

1. Fragile, handle very carefully.

2. A timer board contains CMOS (Complementary Metal-Oxide

Semiconductor) integrated circuits, which are susceptible to failure due to static discharge. It is especially important to either wear an anti-static wrist strap or touch a metal part of the machine before servicing to be static free.

3. Do not touch the electronic devices on either side of the board to prevent damage.

4. Do not change wiring and connections. Especially, never misconnect terminals.

5. Do not repair the electronic devices or parts on the board in the field.

Always replace the whole board assembly when it fails.

The icemaker is controlled by the Timer Board for the following purposes:

1) To prevent the Gear Motor and the Compressor from starting or stopping simultaneously.

2) To reduce ice remaining in the Evaporator.

3) To protect the unit in case of low water and low water pressure.

4) To protect the unit from short cycling if the Bin Control resets quickly.

8

[c] SEQUENCE

Fig. 1

Fig. 2

9

CONTROL (CTL)

PROTECT (PRT)

X1 RELAY

(GEAR MOTOR)

X2 RELAY

(COMPRESSOR)

PART CODE

MODEL

RATING

T

1

T

2

T

3

T

4

T

5

T

6

437305-02

H2AA144C02

24 VAC 50/60Hz

60 ± 15 sec.

90 ± 22 sec.

150 ± 45 sec.

Max. 1 sec.

Max. 0.25 sec.

Max. 1 sec.

Fig. 3

Note: “T” (time) functions of the Timer Board are non-adjustable.

10

Functions of Terminals

1) Terminals 1, 2

Power supply AC 24V.

2) Terminals 3, 4

Control X

1

(GM) and X

2

(CM) Relays.

When closed, energize X

1

(GM) in 1 sec. and X

2

(CM) in 60 sec.

When opened, de-energize X

1


2

(CM) in 90 sec.

3) Terminals 5, 6

Control X

1

(GM) and X

2

(CM) Relays.


1

(GM) and X

2

(CM) immediately.


1


2

(CM) in 60 sec.

4) Terminals 7, 8, 9

X

1

(GM) contacts.

8 is a movable contact, 7 is a make contact, and 9 is a break contact.

5) Terminals 10, 11

Control X

2

(CM) Relay.


2

(CM) immediately.


2

(CM) immediately.

Note: 1. X

2

Relay is a single pole, normally open relay, and its terminals are mounted on the relay itself.

2. The above operation times are median. See Fig. 3 for details.

3. GM = Gear Motor

CM = Compressor

11

III. 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 achieve optimum icemaker performance, the following parts need periodic inspection and maintenance:

Extruding head (upper bearing)

Housing (lower bearing)

Mechanical seal

These parts should be inspected after two years from installation or

10,000 hours of operation, whichever comes first, and once a year thereafter. Their service life, however, depends on water quality and environment. More frequent inspection and maintenance are recommended in bad or severe water conditions.

1. EXTRUDING HEAD (UPPER BEARING), HOUSING (LOWER 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.

0.5 mm Round Stock or Pin Gauge

Auger

Extruding

Head

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.)

For reference only

(May differ from actual design)

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.

12

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.

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

Plastic mesh Air Filters remove dirt or dust from the air and keep the Condenser from getting clogged. If the Filters get clogged, the ice dispenser’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.

3) Rinse and dry the Air Filter thoroughly, and place it in position.

Air Filter

Louver

Fig. 4

13

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

Packing

Inlet Hose

Fig. 5

14

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.

15

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.

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.

16

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.

17

IV. TECHNICAL INFORMATION

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

18

2. CONTROL BOX

19

3. WIRING DIAGRAM

20

4. TIMING CHART

[a] PRINCIPLE OF OPERATION

When the Operation Switch is moved to the “ON” position, water is supplied through the

Control Water Valve. This cycle continues until the Reservoir is full and the Float Switch signals to close the Water Valve. The Gear Motor will then start in 1 second and the

Compressor in 60 seconds. This starts the normal icemaking process.

During normal operation, the icemaker will stop only when the Ice Storage Bin is full and the Bin Control activates. This will automatically reset to resume normal operation.

POWER ON BIN FULL

Float Switch

UPPER

LOWER

Control Water Valve

Bin Control Switch

Gear Motor

Fan Motor

Compressor

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

1sec 90sec

60sec 150sec

1sec

60sec

Fig. 6

[b] PROTECTORS

1) Pressure Switch

If the Pressure Switch activates, the Gear Motor, Fan Motor and Compressor stop simultaneously in 0.25 sec. When the switch resets at the correct pressure, the icemaker starts the icemaking process in the same way as startup. (See “[a] PRINCIPLE OF

OPERATION.”)

Although the Pressure Switch will automatically reset, the Compressor will stop for at least 5 minutes for protection in case the head pressure rises to activate the Pressure

Switch again. If this happens, the icemaker will start and stop repeatedly without making ice until the cause of head pressure rise is removed.

2) Motor Protector (GM)

When the Protector activates, the Gear Motor, Fan Motor and Compressor stop simultaneously in 0.25 sec. The Protector has to be manually reset. Check and resolve the cause of the Protector tripping before pressing the Reset.

21

Float Switch

Control Water Valve

Pressure Switch

Gear Motor

Fan Motor

Compressor

POWER ON

UPPER

LOWER

PRESSURE SWITCH

MOTOR PROTECTOR

OFF RESET

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

1sec 0.25sec

60sec

1sec

60sec

Fig. 7

3) Low Water Control

The icemaker will stop when the water level in the Reservoir falls below the lower float level and is not refilled to the upper float level within 90 seconds due to either an interruption in the water supply or low water pressure. When the water reaches the upper float level, the icemaker will automatically resume the icemaking process.

LOW WATER

Float Switch

POWER ON

UPPER

LOWER

Control Water Valve

Gear Motor

Fan Motor

Compressor

ON

OFF

ON

OFF

ON

OFF

ON

OFF

1sec 90sec

60sec 150sec

1sec

60sec

Fig. 8

22

5. PERFORMANCE DATA

[a] FM-170AFE

200

180

160

140

120

100

10/10 21/15 32/21

Ambient Temp/Water Temp (°C)

14.5

14

13.5

13

16

15.5

15

10/10 21/15 32/21


1.2

1

0.8

0.6

0.4

0.2

0

Head Pressure (MPa)

Suction Pressure (MPa)

10/10 21/15 32/21


0.12

0.1

0.08

0.06

0.04

0.02

0

23

[b] FM-170AFE-N

140

120

100

200

180

160

10/10 21/15 32/21


16

15.5

15

14.5

14

13.5

13

1.2

1

0.8

0.6

0.4

0.2

0

10/10 21/15 32/21


Head Pressure (MPa)

Suction Pressure (MPa)

0.12

0.1

0.08

0.06

0.04

0.02

0

10/10 21/15 32/21


24

V. SERVICE DIAGNOSIS

1. NO ICE PRODUCTION

PROBLEM CHECK POSSIBLE REMEDY

[1] The icemaker will not start. a) Power Supply 1. OFF position. 1. Move to ON position. b) Circuit Breaker

(Control Box)

3. Bad contacts.

4. Blown fuse.

5. Unplugged.

1. OFF position.

2. Bad contacts.

1. Disconnected.

3. Check for continuity and replace.

4. Replace.

5. Plug in.

1. Move to ON position.


1. Connect. c) Transformer

Receptacle (on upper part of

Control Box) d) Transformer e) Water Valve f) Water Supply Tap g) Plug and

Receptacle

(Control Box) h) Bin Control i) Protection Switch

1. Coil winding opened. 1. Replace.


2. Strainer clogged.

1. Closed.

2. Clean.

1. Open.

2. Water failure.

1. Disconnected.

2. Wait till water is supplied.

1. Connect.

2. Terminal out of Plug or Receptacle.

1. Bad contacts.

2. Actuator does not move freely.

2. Insert Terminal back in position.


2. Clean Axle and its corresponding holes or replace Bin Control.

1. Bin Control defective. 1. Check Bin Control and replace.

2. Switch turned on. 2. Check Protection Switch.

[2] Water does not stop, and the icemaker will not start. a) Water Control

Relay b) Float Switch

[3] Water has been supplied, but the icemaker will not start. c) Hoses a) Water Control

Relay b) Gear Motor

Protector c) Gear Motor Relay

(Control Timer) d) Control Timer

(Printed Circuit

Board)


1. Bad contacts. 1. Check for continuity and replace.

2. Float does not move freely.

2. Clean or replace.

1. Disconnected.

1. Bad contacts.

1. Connect.


1. Tripped. 1. Find the cause, resolve it, and press Reset Button on

Motor Protector.



1. Broken. 1. Replace.

25


[3] (Continued) e) Gear Motor

Protect Relay f) Pressure Switch

1. Coil winding opened.

2. Bad contacts.

1. Dirty Air Filter or

Condenser.

2. Ambient temperature too warm.

3. Fan not rotating.

4. Refrigerant overcharged.

5. Refrigerant line or components plugged.

6. Bad contacts.

1. Replace.


1. Clean.

2. Check for recommended temperature.

3. See 3 - [1] - a).

4. Recharge.

5. Clean and replace Drier.


[4] Gear Motor starts, but

Compressor will not start or operates intermittently. a) X2 Relay on

Control Timer b) Starter


2. Coil winding opened. 2. Replace Timer.



[5] Gear Motor and

Compressor start, but no ice is produced. c) Start Capacitor or

Run Capacitor d) Compressor

1. Defective. e) Power Supply a) Refrigerant Line

1. Replace.

2. Motor winding opened or earthed.

3. Motor Protector tripped.

1. Circuit Ampacity too low.

1. Gas leaks.

2. Refrigerant line clogged.

2. Replace.

3. Find out the cause of overheat or overcurrent.

1. Install a larger-sized conductor.

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.

26

2. LOW ICE PRODUCTION


[1] Low ice production. a) Refrigerant Line b) High-side

Pressure Too

High c) Expansion Valve

(not adjustable)

1. Gas leaks.

2. Refrigerant line clogged.

3. Overcharged.

1. Dirty Air Filter or

Condenser.

1. See 1 - [5] - a).

2. Replace the clogged component.

3. Recharge.

1. Clean.

2. Ambient temperature too warm.

2. Check for recommended temperature.

3. Fan rotating too slow. 3. See 3 - [1] - a).

4. Bad ventilation. 4. Remove anything blocking vents.

1. Replace. 1. Low-side pressure too low.

2. Low-side pressure too high.

2. See if Expansion Valve

Bulb is mounted properly, and replace the valve if necessary.

3. OTHERS


[1] Abnormal noise a) Fan Motor b) Compressor

1. Bearing worn out. 1. Replace.

2. Fan blade deformed. 2. Replace fan blade.

3. Replace. 3. Fan blade does not move freely.

1. Bearings worn out, or cylinder valve broken.

1. Replace.

2. Reinstall. 2. Mounting pad out of position. c) Refrigerant Lines 1. Rub or touch lines or other surfaces. d) Gear Motor 1. Bearing or Gear wear/damage. e) Evaporator 1. Too much pressure loss.

2. Scale on inside wall of

Freezing Cylinder.

1. Reset or secure pipes.

1. Replace.

1. Replace.

2. Remove Auger. Use a solution of lime removing cleaner to clean periodically.

If water is found to surpass the following levels, install a conditioner.

3. Water does not flow from Reservoir into

Evaporator (air staying in Evaporator).

Silica

3. Straighten bent hose.

27


[2] Overflow from

Reservoir

(Water does not stop.)

[3] Gear Motor

Protector operates frequently.

[4] Icemaker does not stop even if

Bin is full of ice.

[5] Water leaks at the bottom of

Evaporator a) Water Supply b) Water Valve

1. Water pressure too high.

1. Diaphragm does not close.

1. Install a Pressure

Reducing Valve.

1. Clean or replace. c) Float Switch d) Water Control

Relay

1. Bad contacts.

1. Bad contacts.


1. Check for continuity and replace. a) Power Supply

Voltage


1. Too high or too low. 1. Connect the unit to a power supply of proper voltage.

1. Replace Bearing or Auger.

b) Evaporator Assy 1. Bearings or Auger worn out. c) Bin Control 1. Actuator does not move freely.

1. Clean Axle and its corresponding holes or replace Bin Control. a) Bin Control a) Mechanical Seal

1. Contacts fused.

2. Actuator does not move freely.

1. Worn out.

2. Bad assembly.


2. Clean Axle and its corresponding holes or replace Bin Control.

1. Replace.

2. Clean and assemble.

28

VI. REMOVAL AND REPLACEMENT OF COMPONENTS

1. SERVICE FOR REFRIGERANT LINES

[a] SERVICE INFORMATION

1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture

[R134a]

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 R134a, except when they uses the same lubricant.

2) Treatment for Refrigerant Leak [R134a]

If a refrigerant leak occurs in the low side of an ice maker charged with R134a, 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 easily absorbs a lot of moisture. If an ice maker charged with R134a has possibly drawn in air, the drier must be replaced. Be sure to use a drier designed for R134a.

3) Handling of Handy Flux [R134a]

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 [R134a]

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 and let it into the tubing, or wax contained in the oil will clog the capillary tubing.

5) Service Parts for R134a

Some parts used for refrigerants other than R134a are similar to those for R134a. But never use any parts unless they are specified for R134a because their endurance against the refrigerant have not been evaluated. Also, for R134a, do not use any parts that have been used for other refrigerants. Otherwise, wax and chlorine remaining on the parts may adversely affect R134a.

6) Replacement Copper Tubing [R134a]

The copper tubes currently in use are available for R134a. 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.)

29

7) Evacuation, Vacuum Pump and Refrigerant Charge [R134a]

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 R134a.

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 R134a 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. No refrigerant

Access Valve is provided in the unit. Install a proper Access Valve on the low-side line (ex.

Compressor Process Pipe). Recover the refrigerant from the Access Valve, and store it in a proper container. Do not discharge the refrigerant into the atmosphere.

[c] EVACUATION AND RECHARGE

1) Attach Charging Hoses, a Service Manifold and a Vacuum Pump to the system.

2) Turn on the Vacuum Pump.

3) Allow the Vacuum Pump to pull down to a 760 mmHg vacuum. Evacuating period depends on pump capacity.

4) Close the Low-side Valve on the Service Manifold.

5) Disconnect the Vacuum Pump, and attach either a Refrigerant Charging Cylinder with visual weight indications or a Service Cylinder and electronic scales to accurately weigh in the charge. Remember to loosen the connection on the Charging

Hose to purge the air. Check the Nameplate for the required refrigerant charge.

6) Open the Low-side Valve. Do not invert the Charging Cylinder. A liquid charge may damage the Compressor.

7) Plug in the icemaker when charging speed gets slow. Unplug the icemaker when the

Low-side Gauge shows approximately 0 bar. Do not run the icemaker at negative pressures. Close the Low-side Valve when the charging is complete.

30

8) Repeat the above step 7), if necessary, until the required amount of refrigerant has entered the system.

9) Close the Refrigerant Access Valve, and disconnect the hoses and Service Manifold.

10) Cap the Access Valve and leak test.

2. BRAZING

DANGER

1. Refrigerant R134a itself is not flammable, explosive and poisonous.

However, when exposed to an open flame, R134a 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.

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.


2) Remove the Top Panel, the Front Panel (Left) and the Left Side Panel.

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.

5) Remove the Discharge, Suction and Access Pipes from the Compressor using brazing equipment.

31

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.

8) Attach the Rubber Grommets of the previous Compressor to the new Compressor.

9) Clean the Suction, Discharge and Process Pipes with an abrasive cloth/paper.

10) Place the Compressor in position, and secure it using the Bolts.

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.

15) Connect the Terminals to the Compressor, and replace the Terminal Cover in its correct position.

16) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required refrigerant charge. (See “1. [c] EVACUATION AND RECHARGE”.)

17) Refit the panels in their correct position.

18) Plug in the icemaker.

Note: Hoshizaki recommends that Compressor starting electrics are always replaced at the same time as the Compressor.

32

4. DRIER

IMPORTANT





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.


7) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required refrigerant charge.



33

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.




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.


9) Attach the Bulb to the suction line. Be sure to secure the Bulb using a band and to refit the insulation.

10) Place the new set of Expansion Valve Covers in position.

11) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required refrigerant charge.



34

6. EVAPORATOR ASSEMBLY - See Fig. 9



3) Remove the Inlet Hose from the water tap, and drain the Hose.


5) Unhook the Drain Hose, and remove the Cap on the hose end to drain the water system.

6) Remove the three Thumbscrews, and take off the Spout from the Evaporator.

CUTTER

7) Loosen the Cutter by a wrench and remove it.

8) Remove the Cylinder Gasket at the top of the Evaporator.

EXTRUDING HEAD

9) Remove the three Sealing Bolts, and lift off the Extruding Head from the top of the

Evaporator.

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.

35


IMPORTANT


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 Lower

Bearing Housing.

18) Lift off the Evaporator.

LOWER BEARING 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.

36

GEAR MOTOR

22) Remove the Coupling - Spline on the Gear Motor Shaft.

23) Cut the Connectors of the Gear Motor.

24) Remove the three Socket Head Cap Screws securing the Gear Motor.

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.

26) Assemble the removed parts in the reverse order of which they were removed.

WARNING

Be careful not to damage 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.




37

Gear Motor

Cutter

(FM-170AFE-N)

Cutter

(FM-170AFE)

Sealing Bolt

Flange

Extruding Head

(FM-170AFE-N)

Ring

Mechanical Seal

O-ring

Housing

Coupling - Spline

Extruding Head

(FM-170AFE)

Evaporator

Split Lock Washer

Socket Head

Cap Screw

Auger

Fig. 9

38

7. FAN MOTOR



3) Remove the wire connectors from the Fan Motor leads.

4) Remove the Fan Motor Bracket and the Fan Motor.

5) Install the new Fan Motor onto the Bracket, and re-fix the Fan Blade.

6) Refit the Fan Motor Assembly and the wire connectors.



8. FLOAT SWITCH




4) Remove the Top Panel and the Front Panel (Left).

5) Drain the water system using the Drain Hose (Water Level Gauge).

6) Disconnect the wire connectors of the Float Switch leads.

7) Unfasten the flanged top, turn it and then remove the Float Switch.

8) Install the new Float Switch.

9) Re-connect the switch leads using new connectors.



12) Plug in the icemaker, and check the Float Switch functions normally.

39

9. CONTROL WATER VALVE




4) Remove the Top Panel and the Front Panel (Left).

5) Disconnect the Terminals from the Control Water Valve.

6) Loosen the Fitting Nut on the Control Water Valve Inlet, and remove the Control

Water Valve. Do not lose the Packing inside the Fitting Nut.

7) Remove the Reservoir Inlet Cover from the Control Water Valve.

8) Install the new Control Water Valve.

9) Assemble the removed parts in the reverse order of which they were removed.


11) Check for water leaks.



40

Hoshizaki FM-170AFE-N Service manual

HOSHIZAKI

MODULAR ICE MAKER

MODEL

SERVICE MANUAL

CONTENTS

I. SPECIFICATIONS

1. DIMENSIONS/CONNECTIONS

2. SPECIFICATIONS

II. GENERAL INFORMATION

1. CONSTRUCTION

2. OPERATION - How it works

3. TIMER BOARD

CAUTION

Fig. 1

Fig. 2

Fig. 3

III. MAINTENANCE AND CLEANING INSTRUCTIONS

IMPORTANT

1. EXTRUDING HEAD (UPPER BEARING), HOUSING (LOWER BEARING)

2. MECHANICAL SEAL

3. GEAR MOTOR

4. CONDENSER

5. AIR FILTER

Fig. 4

6. WATER VALVE

Fig. 5

7. CLEANING OF WATER SYSTEM

WARNING

IMPORTANT

8. PERIODICAL CLEANING

IV. TECHNICAL INFORMATION

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

2. CONTROL BOX

3. WIRING DIAGRAM

4. TIMING CHART

Fig. 6

Fig. 7

Fig. 8

5. PERFORMANCE DATA

V. SERVICE DIAGNOSIS

1. NO ICE PRODUCTION

2. LOW ICE PRODUCTION

3. OTHERS

VI. REMOVAL AND REPLACEMENT OF COMPONENTS

1. SERVICE FOR REFRIGERANT LINES

2. BRAZING

DANGER

3. COMPRESSOR

IMPORTANT

WARNING

4. DRIER

IMPORTANT

5. EXPANSION VALVE

IMPORTANT

WARNING

6. EVAPORATOR ASSEMBLY - See Fig. 9

IMPORTANT

WARNING

WARNING

Fig. 9

7. FAN MOTOR

8. FLOAT SWITCH

9. CONTROL WATER VALVE

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