Hoshizaki America, Inc.
Hoshizaki
Modular Cubelet
Serenity Series
Model
FS-1022MLH-C
Including
Condensing Unit Model
SRC-10H
SERVICE MANUAL
“A Superior Degree
of Reliability”
Number: 73186
Issued: 6-9-2011
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IMPORTANT
This manual should be read carefully before the icemaker is serviced or
maintenance operations are performed. Only qualified service technicians
should install, service, and maintain the icemaker. Read the warnings contained
in this booklet carefully as they give important information regarding safety.
Please retain this booklet for any further reference that may be necessary.
CONTENTS
Important Safety Information ................................................................................................. 5
I. Specifications...................................................................................................................... 7
A. Icemaker ....................................................................................................................... 7
B. Condensing Unit............................................................................................................ 8
II. General Information........................................................................................................... 9
A. Construction.................................................................................................................. 9
1. Icemaker .................................................................................................................. 9
2. Condensing Unit.................................................................................................... 10
3. Icemaking Unit........................................................................................................11
B. Sequence of Operation ............................................................................................... 12
1. Sequence Cycles and Shutdown ........................................................................... 12
a) Fill Cycle .......................................................................................................... 12
b) Ice Purge Cycle................................................................................................ 12
c) Freeze Cycle .................................................................................................... 12
d) Drain Cycle ..................................................................................................... 13
e) Shutdown Cycle............................................................................................... 14
2. Sequence Flow Chart............................................................................................ 15
C. Control Board.............................................................................................................. 16
1. Control Board Layout ............................................................................................. 17
2. LED Lights and Audible Alarm Safeties ................................................................. 18
3. Controls and Adjustments...................................................................................... 19
a) Default Dip Switch Settings.............................................................................. 19
b) Infrared Sensor Shutdown Delay (S1 dip switch 1, 2, 3).................................. 19
c) Drain Frequency Control (S1 dip switch 4)....................................................... 20
d) Continuous Dispensing Timer (S1 dip switch 5 & 6)........................................ 20
e) Bin Control Selector (S1 dip switch 7).............................................................. 20
f) Mechanical Bin Control Shutdown Delay (S1 dip switch 8) .............................. 21
g) Factory Use (S1 Dip Switch 9 & 10)................................................................. 21
III. Technical Information...................................................................................................... 22
A. Water Circuit and Refrigeration Circuit........................................................................ 22
B. Wiring Diagrams.......................................................................................................... 23
1. FS-1022MLH-C...................................................................................................... 23
2. SRC-10H ............................................................................................................... 24
C. Performance Data ....................................................................................................... 25
3
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IV. Service Diagnosis........................................................................................................... 26
A. Ice Production Check .................................................................................................. 26
B. Diagnostic Procedure.................................................................................................. 26
C. Control Board Check................................................................................................... 30
D. Bin Control Check ....................................................................................................... 33
1. Infrared Sensor Check ........................................................................................... 33
2. Mechanical Backup Bin Control Check.................................................................. 34
E. Float Switch Check and Cleaning ............................................................................... 36
1. Float Switch Check ................................................................................................ 36
2. Float Switch Cleaning............................................................................................ 36
F. Diagnostic Charts ........................................................................................................ 38
V. Removal and Replacement of Components .................................................................... 41
A. Service for Refrigerant Lines....................................................................................... 41
1. Refrigerant Recovery ............................................................................................. 42
2. Brazing .................................................................................................................. 42
3. Evacuation and Recharge (R-404A)...................................................................... 42
B. Important Notes for Component Replacement............................................................ 43
1. Upper Bearing Wear Check ................................................................................... 45
2. Removal and Replacement of Cutter..................................................................... 45
3. Removal and Replacement of Extruding Head...................................................... 46
4. Removal and Replacement of Auger ..................................................................... 46
5. Removal and Replacement of Evaporator............................................................. 47
6. Removal and Replacement of Mechanical Seal and Lower Housing ................... 48
7. Removal and Replacement of Gear Motor............................................................. 49
VI. Cleaning and Maintenance............................................................................................. 51
A. Cleaning and Sanitizing Instructions........................................................................... 51
1. Cleaning Solution................................................................................................... 51
2. Cleaning Procedure............................................................................................... 51
3. Sanitizing Solution................................................................................................. 53
4. Sanitizing Procedure - Initial .................................................................................. 53
5. Sanitizing Procedure - Final................................................................................... 54
B. Maintenance................................................................................................................ 55
C. Preparing the Icemaker for Long Storage ................................................................... 57
4
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Important Safety Information
Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, or damage to the unit.
WARNING
Indicates a hazardous situation which could result in death or
serious injury.
CAUTION
IMPORTANT
Indicates a situation which could result in damage to the unit.
Indicates important information about the use and care of the
unit.
WARNING
This icemaker should be destined only to the use for which it has been
expressly conceived. Any other use should be considered improper and
therefore dangerous. The manufacturer cannot be held responsible for injury or
damage resulting from improper, incorrect, and unreasonable use.
To reduce the risk of death, electric shock, serious injury, or fire, follow
basic precautions including the following:
• This unit should be disassembled or repaired only by qualified service
personnel to reduce the risk of electric shock, injury, or fire.
• Move the power switch to the "OFF" position. Unplug the icemaker from the
electrical outlet and turn off the power supply to the condensing unit before
any servicing is undertaken. Place the disconnect (if applicable) in the off
position. Lockout/Tagout to prevent the power supply from being turned back
on inadvertently.
• Make sure the icemaker power switch is in the "OFF" position before plugging
in or unplugging the icemaker to reduce the risk of electric shock.
• Do not make any alterations to the icemaker or condensing unit. Alterations
could result in electric shock, injury, fire, or damage to the units.
For FS
• The icemaker requires an independent power supply of proper capacity. See
the nameplate for electrical specifications. Failure to use a properly sized
breaker or fuse can result in a tripped breaker, blown fuse, or damage to
existing wiring. This could lead to heat generation or fire.
• THIS UNIT MUST BE GROUNDED. This unit is equipped with a 3-prong
grounding plug to reduce the risk of potential shock hazards. It must be
plugged into a properly grounded, independent wall outlet. If the outlet is a
2-prong outlet, it is your personal responsibility to have a qualified electrician
replace it with a properly grounded, independent 3-prong wall outlet. Do not
remove the ground prong from the power cord and do not use an adapter plug.
• Do not use an extension cord.
• To reduce the risk of electric shock, make sure the power switch is in the "OFF"
position before plugging in or unplugging the unit.
5
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For FS - Continued
• To reduce the risk of electric shock, do not touch the plug or power switch with
damp hands.
• Do not use a unit with a damaged power cord. The power cord should not be
altered, jerked, bundled, weighed down, pinched, or tangled. Such actions
could result in electric shock or fire. To unplug the unit, be sure to pull the plug,
not the cord, and do not jerk the cord.
• Do not place fingers or any other objects into the ice discharge opening.
For SRC
• Electrical connection must be hard-wired and must meet national, state, and
local electrical code requirements. Failure to meet these code requirements
could result in death, electric shock, serious injury, fire, or severe damage to
equipment.
• The remote condensing unit requires an independent power supply of proper
capacity. See the nameplate for electrical specifications. Failure to use a
properly sized breaker or fuse can result in a tripped breaker, blown fuses, or
damage to existing wiring. This could lead to heat generation or fire.
• THIS UNIT MUST BE GROUNDED. Failure to properly ground the remote
condensing unit could result in death or serious injury.
• Lockout/Tagout to prevent the power supply from being turned back on
inadvertently.
6
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I. Specifications
A. Icemaker
1. FS-1022MLH-C
AC SUPPLY VOLTAGE
GEAR MOTOR
OTHER
MAXIMUM FUSE SIZE
MAX. HACR BREAKER (USA ONLY)
MAX. CIRC. BREAKER (CANADA ONLY)
MINIMUM CIRCUIT AMPACITY
APPROXIMATE ICE PRODUCTION
PER 24 HR.
115/60/1
120 V
120 V
15 A
3 FLA
0.03A
1/4 HP
15 A
15 A
15 A
Ambient
Temp.(°F)
70
WATER TEMP. (°F)
70
50
90
lb./day (kg/day)
*830 (380)
765 (350)
710 (325)
660 (300)
805 (365)
750 (340)
*705 (320)
650 (295)
785 (355)
730 (330)
680 (310)
*600 (275)
Reference without *marks
80
90
100
SHAPE OF ICE
Cubelet
ICE QUALITY
Approx. 80%, Ice (90/70°F, Conductivity 200 µs/cm)
N/A
APPROXIMATE STORAGE CAPACITY
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
ELECTRIC W (kWH/100 lbs.)
POTABLE WATER
90/70°F
70/50°F
FS-1022MLH-C & SRC-10H
FS-1022MLH-C ONLY
1745 (5.96)
331 (1.13)
84 (12)
1713 (4.94)
345 (1.00)
100 (12)
gal./24HR (gal./100 lb.)
EXTERIOR DIMENSIONS (WxDxH)
EXTERIOR FINISH
22"x16.5"x26" (560x417x657mm)
Stainless Steel
WEIGHT
CONNECTIONS - ELECTRIC
- WATER SUPPLY
Net 126 lb. (57 kg), Shipping 166 lb. (75 kg)
Cord Connection
Inlet 1/2" FPT
- DRAIN
Outlet 3/4" FPT
- REFRIGERATION
CIRCUIT
Suction line 1-1/16-12 UNF Fitting (#10 PARKER)
Liquid line 5/8-18 UNF Fitting (#6 PARKER)
Auger type
Direct Driven Auger (1/4 HP Gear Motor)
Float Switch
ICE MAKING SYSTEM
HARVESTING SYSTEM
ICE MAKING WATER CONTROL
COOLING WATER CONTROL
BIN CONTROL SYSTEM (Primary)
BIN CONTROL SYSTEM (Secondary)
CONDENSING UNIT
N/A
Photoelctric Sensor
Mechanical Bin Control (Proximity Switch)
Air-Cooled Remote Condensing unit SRC-10H Required
Copper Tube on Cylinder
Thermostatic Expansion Valve
Headmaster (C.P.R.) on SRC-10H (210 PSI)
R-404A, 8 lb. 6 oz. (3800 g)
Icemaker: 4 oz. (113 g)
EVAPORATOR
REFRIGERANT CONTROL
REFRIGERANT CHARGE
Condensing Unit: 8 lb. 2 oz. (3687 g)
High 427 PSIG, Low 230 PSIG
Fuse (1A)
Fuse (3A)
Float Switch and Timer
DESIGN PRESSURE
P.C. BOARD CIRCUIT PROTECTION
GEAR MOTOR PROTECTION
LOW WATER PROTECTION
ACCESSORIES -SUPPLIED
-REQUIRED
Spare Fuse
Ice Storage Bin
Condensing Unit: SRC-10H
OPERATING CONDITIONS
VOLTAGE RANGE
AMBIENT TEMP.
104-127VAC
45-100°F
WATER SUPPLY TEMP.
WATER SUPPLY PRESSURE
45-90°F
10-113 PSIG
Note: We reserve the right to make changes in specifications and design without prior
notice.
7
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B. Condensing Unit
1. SRC-10H
AC SUPPLY VOLTAGE
COMPRESSOR
FAN MOTOR
208-230/60/1 (3 Wire w/Neutral for 115VAC)
208-230V
120 V
120 V
20 A
9.6 RLA
3 A
46 LRA
MAX
OTHER
0.5 A
MAXIMUM FUSE SIZE
MAX. HACR BREAKER (USA ONLY)
MAX. CIRC. BREAKER (CANADA ONLY)
MINIMUM CIRCUIT AMPACITY
EXTERIOR DIMENSIONS (WxDxH)
DIMENSIONS WITH LEGS (WxDxH)
EXTERIOR FINISH
20 A
20 A
20 A
28"x23"x19" (711x280x485mm)
28"x23"x36" (711x280x915mm)
Galvanized Steel
WEIGHT (Approximate)
CONNECTIONS - ELECTRIC
- REFRIGERATION
CIRCUIT
COMPRESSOR
Net 143 lb. (65 kg), Shipping 169 lb. (77 kg)
Permanent - Connection
Suction Line 1 1/16"-12 UNF Fitting (#10 PARKER)
Liquid Line 5/8"-18 UNF Fitting (#6 PARKER)
Hermetic, Model RS80-C2E-CAV
Air-Cooled Fin and Tube Type
CONDENSER
FAN MOTOR PROTECTION
REFRIGERATION PROTECTION
REFRIGERANT CONTROL
PUMPDOWN CONTROL
REFRIGERANT CHARGE
Thermal Protector
Auto-Reset High-Pressure Switch, Manual Low-Pressure Switch
Headmaster (C.P.R.) (210 PSI)
Auto-Reset Low-Pressure Switch
R-404A, 8 lb. 6 oz. (3800 g)
Condensing Unit: 8 lb. 2 oz. (3687 g)
Icemaker: 4 oz. (113 g)
DESIGN PRESSURE
COMPRESSOR PROTECTION
ACCESSORIES -SUPPLIED
High 427 PSIG, Low 230 PSIG
Internal Protector
Leg
2 pcs.
Hex Head Bolt w/ Washer 8X16
Hex Nut
8 pcs.
8 pcs.
OPERATING CONDITIONS
VOLTAGE RANGE
AMBIENT TEMP.
HEAT OF REJECTION
187-253 VAC
-4-122°F
10500 BTU/hr
Note: We reserve the right to make changes in specifications and design without prior
notice.
8
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II. General Information
A. Construction
1. Icemaker
a) FS-1022MLH-C
Mechanical Backup
Bin Control
Spout
Inlet Water Valve
Power Cord
Float Switch
Reservoir
Icemaking Unit:
Cutter
Extruding Head
Evaporator
Evaporator Heater
Ice Chute
Strainer
Thermostatic
Expansion Valve
Pump-Down
Solenoid Valve
High-Side
Control Box
Service Valve
Low-Side
Service Valve
Drain Valve
Infrared Sensor
Gear Motor
9
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2. Condensing Unit
a) SRC-10H
Condenser
Fan Motor
Headmaster (C.P.R.)
High-Pressure
Switch
Receiver
High-Side
Service Valve
Compressor
Liquid Line
Connection
Suction Line
Connection
Control Box
Safety Low-Pressure Switch
Control Low-Pressure Switch
10
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3. Icemaking Unit
Cutter
Washer
Extruding Head
Upper Bearing
Seal Bolts and Washers
Evaporator Heater
Auger
Evaporator
Mechanical Seal
Socket Head Cap Screw
and Split Lock Washer
O-Ring
Housing-Lower Bearing
Hex Bolt and Washer
Spline Coupling
Socket Head Cap Screw
and Split Lock Washer
Gear Motor
11
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B. Sequence of Operation
The steps in the sequence are as outlined below. This unit utilizes a control board to
switch the icemaker components on and off as needed. When power is supplied, the
power switch is in the "ON" position, and the control switch is in the "ICE" position,
control board "POWER OK" LED and infrared sensor green LED come on. The "POWER
OK" LED remains on constantly. If the infrared sensor yellow LED is on or flashing, move
ice away from the infrared sensor lens.
This system utilizes a pump-down solenoid valve in the icemaker and a control
low-pressure switch in the condensing unit to control the operation of the Comp and
FMR. This eliminates the need for an electrical connection between the 2 units. When
calling for ice, the control board (X1 on control board) energizes the pump-down
solenoid. The low-side refrigerant pressure rises to 29 PSIG, the control low-pressure
switch (located in the condensing unit) closes, energizing the Comp and FMR. When the
ice level satisfies the infrared sensor bin control (bin full), the unit goes into the shutdown
cycle. The control board de-energizes the pump-down solenoid valve (X1 on CB). The
low-side refrigerant pressure drops (unit pumping down). When the low-side pressure
drops to 9 PSIG, the control low-pressure switch opens, de-energizing Comp and FMR.
Control Low-Pressure Switch Settings: Cut-Out: 9 PSIG. Differential: 20 PSIG.
Cut-In: 29 PSIG.
1. Sequence Cycles and Shutdown
a) Fill Cycle
"WTRIN" LED is on. WV energizes and fill cycle begins. 90-second low water safety
timer starts. When UF/S closes, WV de-energizes, and 90-second low water safety timer
resets. 30-second GM delay timer starts. If 90-second low water safety timer terminates
before UF/S closes, WV remains energized, and a 1-beep alarm sounds.
b) Ice Purge Cycle
"GM" LED is on. 30-second GM delay timer terminates. GMR (X2 on CB), GM, GMPR,
and EH energize. 5-minute ice purge timer starts: GM runs for 5 minutes to clear any
ice from the evaporator. To bypass, press the "SERVICE" button on CB after GM starts.
WARNING! Risk of electric shock. Care should be taken not to touch live terminals.
Note: UF/S must be closed before GMR will energize.
c) Freeze Cycle
"COMP" and "GM" LEDs are on. 5-minute ice purge timer terminates. GMR (X2 on
CB), GM, GMPR, and EH continue. CR (X1 on CB) and PDS energize. When CLPS (in
SRC) closes, MC energizes, allowing Comp and FMR to energize. CCH de-energizes.
As water in the evaporator cools, ice starts forming within 4 to 6 minutes. This time frame
depends on the inlet water and ambient temperature conditions. UF/S and LF/S operate
WV as needed to continue the ice making process. This continues until IS activates
allowing CB to de-energize X1 on CB and PDS. The unit goes into pump-down, CLPS
opens, MC de-energizes, de-energizing Comp and FMR. CCH energizes.
12
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d) Drain Cycle
(1) 1-in-1 Drain Cycle: DV energizes for 2 seconds once every hour when the
1-in-1 drain cycle is activated (S1 dip switch 4 in the off position (factory default
position)). 1-hour drain cycle timer terminates, 2-second DT starts. DV energizes for
2 seconds. 2-second DT terminates, 1-hour DT resets. All components and icemaking
continue. This setting is recommended for optimum icemaker performance. The
1-in-1 drain cycle allows any sediment to drain from the evaporator without interrupting
the icemaking process.
(2) 1-in-12 Drain Cycle (optional): DV energizes for ten minutes once every
12 hours when the 1-in-12 drain cycle is activated (S1 dip switch 4 in the "ON"
position (optional)). 12-hour drain cycle timer terminates, CR (X1 on CB) and PDS
de-energize, GMR (X2 on CB), GM, GMPR, and EH continue. Unit is in pump-down
mode. Once the low-side pressure drops to 9 PSIG, CLPS opens, de-energizing MC,
Comp, and FMR. 5-minute ice purge timer begins. When the 5-minute ice purge timer
terminates, GMR (X2 on CB), GM, GMPR, and EH de-energize. 10-minute DT begins,
DV energizes. After 10-minute DT terminates, 12 hour drain cycle timer starts.
(3) Manual Drain: Manual drain is used when servicing evaporator components and
cleaning and sanitizing the unit. When the unit is making ice and the control switch is
moved to the "DRAIN" position, there is a 3-second delay, then CR (X1 on CB) and
PDS de-energize. Unit is in pump-down mode. Once the low-side pressure drops to
9 PSIG, CLPS opens, de-energizing MC, Comp, and FMR. 5-minute ice purge timer
begins. When the 5-minute ice purge timer terminates, GMR (X2 on CB), GM, and
GMPR de-energize. DV energizes to drain the evaporator and reservoir. To avoid the
5-minute shutdown delay, turn off the icemaker power supply, then move the control
switch to the "DRAIN" position. DV de-energizes when the control switch is moved to
the "ICE" position.
13
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e) Shutdown Cycle
(1) Infrared Sensor: When power is supplied to the icemaker, the green LED on IS
turns on. The green LED remains on constantly. As ice fills the storage bin to the
level of activating IS, IS yellow LED turns on (flashing or steady). The yellow LED
flashes when ice is at the outer limit of its range and turns steady as ice nears. After
the yellow LED turns on (flashing or steady), IS shutdown delay timer (S1 dip switch
1, 2, 3) begins. For a typical dispenser unit application, a 100-second shutdown delay
is recommended. When used with a standard Hoshizaki storage bin, any shutdown
delay setting is acceptable. See "II.C.3.b) Infrared Sensor Shutdown Delay (S1 dip
switch 1, 2, 3)." Once IS shutdown delay timer terminates, CR (X1 on CB) and PDS
de-energize and the 5-minute ice purge timer begins. Unit is in pump-down mode.
Once the low-side pressure drops to 9 PSIG, CLPS opens, de-energizing MC, Comp,
and FMR. When the 5-minute ice purge timer terminates, GMR (X2 on CB), GM, and
GMPR de-energize.
Note: If IS fails to shut down the icemaker, MBC opens, CB shuts down the icemaker,
and a 9-beep alarm sounds.
(2) Mechanical Backup Bin Control: CB shuts down the entire unit within 10 seconds
when MBC opens (actuator paddle engaged), and sounds a 9-beep alarm.
Legend: CB–control board; CCH–crankcase heater; CLPS–control low-pressure
switch; Comp–compressor; CR–compressor relay (pump-down solenoid);
DT–drain timer; DV–drain valve; EH–evaporator heater; FMR–fan
motor-remote; F/S–float switch; GM–gear motor; GMPR–gear motor protect
relay; GMR–gear motor relay; IS–infrared sensor; LF/S–lower float switch;
MBC–mechanical backup bin control; MC–magnetic contactor;
PDS–pump-down solenoid valve; UF/S–upper float switch; WV–inlet water
valve
14
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2. Sequence Flow Chart
15
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C. Control Board
• A Hoshizaki exclusive control board is employed in Hoshizaki Modular Flakers.
• All models are pre-tested and factory set.
CAUTION
1. The control board is fragile; handle very carefully.
2. The control board contains integrated circuits, which are susceptible to failure
due to static discharge. It is especially important to touch the metal part of
the icemaker before handling or replacing the control board.
3. Do not touch the electronic devices on the control board or the back of the
control board.
4. Do not change wiring and connections. Do not misconnect terminals.
5. Do not short out power supply to test for voltage.
6. Always replace the whole control board assembly if it goes bad.
16
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1. Control Board Layout
"F-A" Control Board
• K9 Connector (5VDC)
#1 & #2 Control Switch
Open: Icemaking
Closed: Drain
• "COMP" LED
(X1 Relay)
Pump-Down
• "GM" LED
(X2 Relay)
Gear Motor
#3 & #4 Jumper
Solenoid Valve
Evaporator Heater
#5 & #6 Gear Motor Protect
Relay Circuit
• "SERVICE" Button
(Ice Purge Cycle Bypass)
• K1 Connector
(115VAC)
#3 115VAC Input
#2 Gear Motor,
Evaporator
• K8 Connector
(24VAC and 5VDC)
Heater
#1 Transformer 24VAC Input
#2 Transformer 24VAC Neutral
#3 & #4 Mechanical Backup Bin
Control (5VDC)
#5 Float Switch Common (5VDC)
#6 Upper Float Switch
#7 Lower Float Switch
• "FLUSH" LED
(X3 Relay)
Drain Valve
• K2 Connector
(24VAC)
#10 Drain Valve
#9 Transformer
24VAC Input
#8 Inlet Water Valve
#7 Transformer
24VAC Input
• K7 Connector-Open
• "POWER OK" LED
• "WTRIN" LED
(X4 Relay)
Inlet Water Valve
• S1 Dip Switch
Water Dispensing
Valve, Agitation
Motor, and Ice
Dispensing LEDs
(not used on this
model)
• K6 Connector (20VDC)
Infrared Sensor Bin Control
Dark Blue
White (signal) (common)
• J2 Connector-Open
• K3 Connector-Open
• K4 Connector-Open
• K5 Connector-Open
Brown (ground)
"F-A" Control Board
2A4296-01
Part Number
17
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2. LED Lights and Audible Alarm Safeties
The "POWER OK" LED indicates proper control voltage and will remain on unless a
control voltage problem occurs. For further details, see "II.B. Sequence of Operation."
Energized
Components
Sequence Step
Fill Cycle
Ice Purge Cycle
Freeze Cycle (with refill) GM, COMP,
LED
WTRIN
GM
Min.
Max.
WV
-
-
GM, EH
GM, EH, PDS, Comp,
5 min.
-
5 min.
*On until UF/S closes.
Alarm sounds after
90 sec.
WTRIN* (refill), FMR,
WV* (refill)
1-in-1 Drain Cycle
FLUSH (Drain) DV
2 sec.
2 sec.
(S1 dip switch 4 off)
GM, COMP
(only if IS not
satisfied)
Comp, GM, EH, PDS,
FMR (only if IS not
satisfied)
1-in-12 Drain Cycle
(S1 dip switch 4 on)
FLUSH (Drain) DV
10 min.
10 min.
The built-in alarm safeties shut down the unit.
No. of Beeps
Type of Alarm
(every 5 sec.)
Reset Options
Automatic reset once water supply is restored
1
Low Water Safety
UF/S open > 90 seconds after WV energized. and UF/S closes.
2
Control Switch
Automatic reset once the control switch is
In "DRAIN" position longer than 15 minutes. moved to the "ICE" position.
3
4
5
High-Pressure Switch: N/A on this model.
High-Pressure Switch: N/A on this model.
Freeze Timer
See "III.B.2. SRC-10H" for high-pressure
switch operation.
Manual reset. Turn power off and on again.
WV off > 30 minutes since last WV activation.
6
7
8
9
Low Voltage
(92VAC 5% or less)
High Voltage
(147VAC 5% or more)
Gear Motor
GMPR contacts fail to close.
Infrared Sensor (S1 dip switch 7)
MBC actuator paddle engaged.
"POWER OK" LED turns off if voltage
protection operates.
The control voltage safeties automatically
reset when voltage is corrected.
Manual reset. Turn power off and on again.
Manual reset. Turn power off and on again.
Legend: DV–drain valve; EH–evaporator heater; FMR–fan motor-remote; GM–gear
motor; IS–infrared sensor bin control; MBC–mechanical backup bin control;
PDS-pump-down solenoid valve; WV–inlet water valve
18
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3. Controls and Adjustments
CAUTION
Dip switches are factory set. Failure to maintain factory settings may adversely
affect performance and warranty coverage. For more information, contact
Hoshizaki Technical Support at 1-800-233-1940.
a) Default Dip Switch Settings
The S1 dip switch settings are factory-set to the following positions:
S1 Dip Switch No.
1
2
3
4
5
6
7
8
9
10
FS-1022MLH-C
ON OFF OFF OFF OFF OFF ON ON OFF OFF
Normally off (factory use)
Mechanical Backup Bin Control Shutdown Delay
Bin Control Selector
Continuous Dispensing Timer
(DCM models only, do not adjust on modular icemakers)
Drain Frequency Control
Infrared Sensor Shutdown Delay
b) Infrared Sensor Shutdown Delay (S1 dip switch 1, 2, 3)
Infrared sensor shutdown delay is the delay between the infrared sensor detecting ice
(yellow LED flashing or steady) and the start of the shutdown sequence. For dispenser
unit applications, the ice level at shutoff may need to be adjusted depending on the
dispenser agitation or dispense method. Increasing the shutdown delay setting allows for
a higher level of ice in the bin before the icemaker shuts down. For a typical dispenser
unit application, a 100-second shutdown delay is recommended. When used with a
standard Hoshizaki storage bin, any shutdown delay setting is acceptable.
WARNING
Increasing the shutdown delay allows a higher level of ice in the dispensing
unit/storage bin before shutdown. This could lead to icemaker movement or ice
overflow.
S1 Dip Switch Setting
Infrared Sensor Shutdown Delay
No. 1 No. 2 No. 3
OFF
ON
OFF
OFF
ON
OFF
OFF
OFF
ON
0 Seconds
100 Seconds (1.6 minutes) (Factory Default)
1100 Seconds (18.3 minutes)
OFF
OFF
OFF
1650 Seconds (27.5 minutes)
ON
OFF
ON
ON
ON
ON
OFF
ON
2200 Seconds (36.7 minutes)
0 Seconds
ON
0 Seconds
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c) Drain Frequency Control (S1 dip switch 4)
This unit is factory set for optimum performance with the 1-in-1 drain cycle (S1 dip
switch 4 in the "OFF" position). This setting allows for removal of sediment from the
evaporator without interrupting the icemaking process. An optional 1-in-12 drain cycle is
available.
S1 Dip Switch Setting
Drain Timer Interval Drain Valve Open
No. 4
OFF (1-in-1)
ON (1-in-12)
1 Hour
2 Seconds
10 Minutes
11 Hours 45 Minutes
d) Continuous Dispensing Timer (S1 dip switch 5 & 6)
DCM models only. The dispense mode switch on DCMs must be in the "CONTINUOUS"
position for this setting to apply. The factory setting allows ice to be dispensed
continuously as long as the dispense solenoid is activated.
S1 Dip Switch Setting
Dispense Time
No. 5
OFF
ON
No. 6
OFF
OFF
ON
No Limit
20 Seconds
60 Seconds
No Limit
OFF
ON
ON
e) Bin Control Selector (S1 dip switch 7)
This unit is factory set for infrared sensor bin control operation. No adjustment is
required. When used on a standard ice storage bin, the mechanical bin control may be
used instead of the infrared sensor by moving S1 dip switch 7 to the off position. In the
factory default position (S1 dip switch 7 in the on position), the gear motor delay after the
upper float switch closes is 30 seconds. When the mechanical bin control is used (S1
dip switch 7 in the off position), the gear motor delay after the upper float switch closes is
5 seconds. WARNING! Do not place S1 dip switch 7 in the off position on dispenser
unit applications.
S1 Dip Switch
Setting
No. 7
OFF
Bin Control Application
Gear Motor Delay
Mechanical Bin Control (Standard Ice Storage Bins Only)
5 seconds
Infrared Sensor with
Mechanical Bin Control Backup
ON
30 seconds
20
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f) Mechanical Bin Control Shutdown Delay (S1 dip switch 8)
Factory set for normal operation. No adjustment is required. The shutdown delay is the
time between the mechanical bin control proximity switch opening and the control board
shutting off the icemaker.
S1 Dip Switch
Setting
Mechanical
Backup
Bin Control
Shutdown Delay
No. 8
OFF
ON
0.25 Seconds
6.7 Seconds
g) Factory Use (S1 Dip Switch 9 & 10)
Factory set for optimum performance. Do not adjust.
21
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III.Technical Information
A. Water Circuit and Refrigeration Circuit
1. FS-1022MLH-C with SRC-10H
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B. Wiring Diagrams
1. FS-1022MLH-C
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2. SRC-10H
*
**
***
* Control Low-Pressure Switch
** Safety Low-Pressure Switch
(Manual Reset)
*** High-Pressure Switch
0
Cut-in
29 0.5PSIG
Cut-out
Cut-in
384 22 PSIG
0
Cut-out
3 2.5 PSIG
6 PSIG
1.0
Differential
Cut-out
20 PSIG
284 22 PSIG
0.5
Differential
9 PSIG
24
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C. Performance Data
1. FS-1022MLH-C with SRC-10H
APPROXIMATE
ICE PRODUCTION
PER 24 HR.
Ambient
Temp. (F)
70
Water Temp. (F)
70
50
90
*832
765
712
663
1713
1727
1740
1775
*100
92
85
80
*14
14
16
378
347
324
301
--
--
--
--
377
347
323
301
-10
-10
-9
803
365
340
320
294
--
--
--
--
364
339
319
293
-10
-9
784
356
331
309
273
--
--
--
--
356
331
308
272
-10
-9
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
747
*703
647
1717
1731
1745
1789
96
90
*84
78
14
16
729
679
*600
1722
1736
1760
1804
94
88
81
*72
14
lbs./DAY ( l/day)
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
gal. / day (l/day)
EVAPORATOR OUTLET TEMP.
F ( C)
16
*16
18
-9
-8
18
-8
-8
18
-8
*18
224
233
242
*279
29
30
31
*33
HEAD PRESSURE
*224
233
242
279
*29
30
15.7
16.4
17.0
19.6
2.0
2.1
2.2
2.3
224
233
*242
279
29
30
*31
33
15.7
16.4
17.0
19.6
2.0
2.1
2.2
2.3
15.7
16.4
17.0
19.6
2.0
2.1
2.2
2.3
PSIG (kg/sq.cmG)
SUCTION PRESSURE
PSIG (kg/sq.cmG)
31
33
HEAT OF REJECTION
1130 BTU/hr AT 90 F/WT 70 F
Note: We reserve the right to make changes in specifications and design without prior
notice.
25
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IV. Service Diagnosis
WARNING
1. This unit should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
2. Risk of electric shock. Use extreme caution and exercise safe electrical
practices.
3. Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.
4. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews
are securely in place after the unit is serviced. Make sure that none have
fallen into the dispenser unit/storage bin.
5. Make sure all food zones in the icemaker and dispenser unit/storage bin are
clean after the unit is serviced. For cleaning procedures, see "VI. Cleaning
and Maintenance."
A. Ice Production Check
To check production, prepare a bucket or pan to catch the ice and a set of scales to
weigh the ice. After the icemaker has operated for 10 to 20 minutes, catch the ice
production for 10 minutes. Weigh the ice to establish the batch weight. Multiply the batch
weight by 144 for the total production in 24 hours.
B. Diagnostic Procedure
This diagnostic procedure is a sequence check that allows you to diagnose the electrical
system and components. Before proceeding, check for correct installation, adequate
water supply (minimum of 10 PSIG, maximum of 113 PSIG) and proper voltage per unit
nameplate. Check that the 24VAC 1A fuse and the 115VAC 3A GM fuse are good. When
checking for high-voltage (115VAC), always choose a white (W) neutral wire to establish
a good neutral connection. When checking for low-voltage (secondary) (24VAC), always
choose a light blue (LBU) neutral wire to establish a good neutral connection. If the
icemaker is in alarm, see "II.C.2. LED Lights and Audible Alarm Safeties."
Note: EH energizes when "GM" LED turns on. CB X1 Comp relay energizes PDS.
Pressure rises in the refrigeration system and closes CLPS. MC is energized
when CLPS closes, energizing Comp and FMR.
1) Remove the front panel, then move the power switch to the "OFF" position.
2) Unplug the icemaker from the electrical outlet.
3) Remove the control box cover and access CB.
4) Check the S1 dip switch settings, see "II.C.3.a) Default Dip Switch Settings" to assure
that they are in the correct positions. For proper operation of IS, confirm that S1 dip
switch 7 is in the "ON" position.
5) Startup – "POWER OK" LED is on. Plug the icemaker into the electrical outlet, then
move the power switch to the "ON" position. Move the control switch to the "ICE"
position. CB "POWER OK" LED and IS green LED should be on. Diagnosis "POWER
OK" LED: CB POWER OK" LED is off. Check for proper supply voltage (115VAC) input
to the control transformer. If 115VAC is not present, check the power switch and breaker.
Next, check for proper 24VAC outpout voltage from the control transformer. Check CB
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K8 connector pin #1 white/red (W/R) to pin #2 light blue (LBU). If 24VAC is not present
and 1A 24VAC fuse is good, replace the control transformer. If 24VAC is present and
"POWER OK" LED is off, CB is bad and must be replaced.
IS Diagnosis: Check that IS green LED is on. If "POWER OK" LED is on and IS green
LED is off, check 20VDC at CB K6 connector brown (BR) wire to dark blue (DBU) wire.
If 20VDC is not present, confirm S1 dip switch 7 is in the "ON" position. If S1 dip switch
7 is in the "ON" position and 20VDC is not present, CB is bad and must be replaced. If
IS yellow LED is on or flashing, move ice away from IS lens. If no ice is present, clean
the lens with a warm, clean damp cloth. If yellow LED is still on or flashing after cleaning
the lens, replace IS. MBC Diagnosis: Move S1 dip switch 7 to the "OFF" position.
Check that the actuator paddle is properly positioned. Check for continuity across
MBC proximity switch. When MBC proximity switch is closed 0VDC is read across
CB K8 connector pin #3 gray (GY)and #4 gray (GY). 5VDC is present between CB
K8 connector pin #3 gray (GY) or #4 gray (GY) to CB white K5 connector pin closest to
red K4 connector (5VDC gnd). If 5VDC is not present, CB is bad and must be replaced.
CB monitors the following switches with 5VDC: Control Switch, Gear Motor Protect
Relay (relay terminals 3 & 5), Float Switch, and Mechanical Bin Control. When 5VDC is
present across any of these switches, the switch is open.
6) Fill Cycle – "WTRIN" LED is on. WV energizes. The 90-second low water safety timer
begins. LF/S closes. Nothing occurs at this time. The reservoir continues to fill until
UF/S closes. The closing of the UF/S de-energizes WV, terminates the 90-second low
water safety timer, and starts the 30-minute freeze timer. Diagnosis: Check that WV
energizes and water fills the reservoir. If not, check for water supply line shut-off valve
closed, clogged water filters, and clogged WV screen. Next, check 24VAC to WV from
CB K2 connector pin #8 white/brown (W/BR) wire to a light blue (LBU) neutral wire.
Check for continuity through WV solenoid. If open, replace WV. If WV is energized and
refill exceeds 90-second low water safety timer (fill timer) with no water in the reservoir,
check for DV leaking. If reservoir is full and overflowing check for open UF/S. Check that
WV shuts off when UF/S closes. If not, check UF/S continuity, red (R) wire to black (BK)
wire. Clean or replace if necessary. See "IV.E. Float Switch Check and Cleaning."
Note: Low Water Safety–If UF/S remains open 90 seconds after WV energizes, a 1-beep
alarm sounds. This alarm resets automatically once UF/S closes.
7) Ice Purge Cycle – "GM" LED is on. WV de-energizes and "WTRIN" LED turns off.
30-second GM delay timer and 30-minute freeze timer start. The 30-second GM delay
timer terminates, GMR (X2 on CB), GM, GMPR, and EH energize. 5-minute ice purge
timer starts. Diagnosis: If "GM" LED is off, check that WV de-energizes and UF/S
closes. If "GM" LED is on and GM is off, confirm 115VAC at CB K1 connector pin #3
brown (BR) to white (W) neutral. Check for 115VAC at CB K1 connector pin #2 white/
black (W/BK) to a white (W) neutral. If no voltage is present, CB is bad and must be
replaced. If 115VAC is present, check GM fuse, GM internal protector, GM windings and
capacitor, and GM coupling between auger and GM.
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8) Freeze Cycle – "GM" and "COMP" LEDs are on. "GM" LED, GMR (X2 on CB),
GM, GMPR, and EH continue. "COMP" LED turns on and PDS energizes. Once the
refrigeration circuit low-side pressure rises to 29 PSIG, CLPS closes, energizing MC,
which energizes Comp and FMR. Ice production begins 4 to 6 minutes after Comp and
FMR energize depending on ambient and water conditions.
FS Diagnosis: Check that "COMP" LED is on and that PDS energizes. If "COMP" LED
is off, check DC voltage across GMPR terminals 3 and 5 white/orange (W/O) wires.
If 5VDC is present, GMPR contacts are open. Check GMPR solenoid voltage and
solenoid continuity. Replace GMPR if necessary. If "COMP" LED remains off, CB is bad
and must be replaced. If "COMP" LED is on and PDS is not energized, confirm 115VAC
at CB X1 relay brown (BR) to white (W) neutral and CB X1 relay dark blue (DBU) to
white (W) neutral. If 115VAC is present on CB X1 brown (BR) and not on CB X1 dark
blue (DBU) CB is bad and must be replaced. Next, check for 115VAC from PDS dark
blue (DBU) to white (W) neutral. If 115VAC is present and PDS is closed, check for
continuity through PDS solenoid. If open or if PDS is sticking closed, replace PDS.
SRC Diagnosis: Confirm that CLPS closes. Once CLPS closes, MC energizes,
energizing Comp and FMR. If not, check CLPS, SLPS (manual reset), and HPS
(automatic reset).
CLPS: When PDS is energized, CLPS closes when refrigeration circuit low-side
pressure rises to 29 PSIG. If CLPS is open, check that refrigeration circuit low-side
pressure has reached 29 PSIG. If refrigeration circuit low-side pressure is too low,
confirm proper TXV operation, check for refrigerant restrictions (drier, PDS), and correct
refrigerant charge. Recover, evacuate, and recharge if necessary.
SLPS: If SLPS is open, manually reset SLPS. Confirm proper TXV operation, check for
refrigerant restriction (drier, PDS), and correct refrigerant charge. Recover, evacuate,
and recharge if necessary.
HPS: HPS automatically resets when refrigeration circuit high-side pressure is within an
acceptable range. If HPS does not reset (open), allow pressures to equalize and HPS
to reset. If refrigeration circuit high-side pressure does not drop, recover, evacuate, and
recharge if necessary. Before restarting unit, check for dirty or clogged condenser. Once
unit is restarted, check for proper FMR operation and fan blade for binding. Check for
refrigeration circuit refrigerant restriction (receiver, service valves, PDS, and drier). Also
check for proper HM operation. If refrigerant pressures have returned to an acceptable
range and HPS does not close, replace HPS.
MC: If MC energizes and Comp does not energize, check 208-230VAC at MC T1 black
(BK) to MC T2 red (R). If 208-230VAC is not present, check incoming power supply and
MC contact continuity. If 208-230VAC is present and Comp does not start, check Comp
start relay, start capacitor, run capacitor, and Comp motor windings. If FMR does not
energize, check 115VAC at MC T3 dark blue (DBU) to white (W) neutral. If 115VAC is
present and FM does not energize, check FM capacitor and motor windings.
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9) Refill Cycle/Low Water Safety Cycle – "GM", "COMP", and "WTRIN" LEDs are on.
As ice is produced, the water level in the reservoir drops. UF/S opens. Nothing happens
at this time. When LF/S opens, WV energizes, 90-second low water safety timer (fill
timer) starts. GMR (X2 on CB), GM, GMPR, EH, PDS, MC, Comp, and FMR continue.
When LF/S closes, nothing happens at this time. When UF/S closes, WV de-energizes,
90-second low water safety timer (fill timer) terminates, and 30-minute freeze timer
starts.
If UF/S remains open 90 seconds after WV energizes (LF/S opens) (fill timer
exceeded), a 90-second shutdown cycle starts. CB X1 relay de-energizes, de-
energizing PDS. Refrigeration circuit low-side pressure drops to 9 PSIG, opening
CLPS. CLPS opens de-energizing MC, Comp, and FMR. CB signals a 1-beep alarm
every 5 seconds. 90-second purge timer starts. GMR (X2 on CB), GM, GMPR, and EH
continue. 90-second purge timer terminates, GMR (X2 on CB), GM, GMPR, and EH
de-energizes. WV and 1-beep alarm continue until UF/S closes.
Diagnosis – Check that "WTRIN" LED is on. If not, check that LF/S is open. See "IV.E.
Float Switch Check and Cleaning." If LF/S is open and "WTRIN" LED is off, CB is bad
and must be replaced. If "WTRIN" LED is on, check that the reservoir fills. If not, check
for water supply line shut-off valve closed, clogged water filters, and clogged WV screen.
Next, check 24VAC to WV from CB K2 connector pin #8 white/brown (W/BR) wire to a
light blue (LBU) neutral wire. Check for continuity through WV solenoid. If open, replace
WV. If WV is energized and refill exceeds 90-second low water safety timer (fill timer)
with no water in the reservoir, check for DV leaking. If reservoir is full and overflowing
check that UF/S closes. If not, check UF/S continuity, red (R) wire to black (BK) wire.
Clean or replace if necessary. See "IV.E. Float Switch Check and Cleaning."
Note: Each time UF/S closes, 30-minute freeze timer starts. The 30-minute freeze timer
resets when UF/S closes again. If UF/S does not close again within 30 minutes,
CB shuts down the unit and sounds a 5-beep alarm every 5 seconds. See
"II.C.2. LED Lights and Audible Alarm Safeties."
10) Shutdown – See "IV.D. Bin Control Check."
Legend: CB–control board; CLPS–control low-pressure switch; Comp–compressor;
DV–drain valve; EH–evaporator heater; FMR–fan motor-remote;
GM–gear motor; GMPR–gear motor protect relay; GMR–gear motor relay;
HM–headmaster; HPS–high-pressure switch; IS–infrared sensor; LF/S–lower
float switch; MC–magnetic contactor; MBC–mechanical backup bin control;
PDS–pump-down solenoid valve; SLPS–safety low-pressure switch;
UF/S–upper float switch; WV–inlet water valve
29
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C. Control Board Check
Before replacing a control board that does not show a visible defect and that you suspect
is bad, always conduct the following check procedure. This procedure will help you
verify your diagnosis. Before proceeding, check for proper voltage per unit nameplate.
Check that the 24VAC 1A fuse and the 115VAC 3A GM fuse are good. When checking
for high-voltage (115VAC), always choose a white (W) neutral wire to establish a good
neutral connection. When checking for low-voltage (secondary) (24VAC), always choose
a light blue (LBU) neutral wire to establish a good neutral connection. If the icemaker is in
alarm, see "II.C.2. LED Lights and Audible Alarm Safeties."
Note: EH energizes when "GM" LED turns on. CB X1 Comp relay energizes PDS.
Refrigeration circuit low-side pressure rises to 29 PSIG, closing the CLPS
contacts. MC is energized when CLPS closes, energizing Comp and FMR.
1) Check the S1 dip switch settings to assure that they are in the factory default position.
For factory default settings, see "II.C.3.a) Default Dip Switch Settings." S1 dip switch
7 determines bin control application:
Bin Control Application:
Infrared Sensor Bin Control with Mechanical Backup Bin Control: S1 dip switch
7 in the "ON" position.
Mechanical Bin Control (Standard Ice Storage Bin): S1 dip switch 7 in the "OFF"
position.
2) Startup – "POWER OK" LED on: Move the control switch to the "ICE" position,
then move the power switch to the "ON" position. The "POWER OK" LED turns on.
Diagnosis "POWER OK" LED: Check that the "POWER OK" LED is on. If not,
check for proper supply voltage (115VAC) input to the CT (main breaker or fuse and
power switch). Next, check for proper low-voltage (24VAC) output from CT and that
the 1A fuse is good. Check for 24VAC from K8 connector pin #1 white/red (W/R) to
K8 connector pin #2 light blue (LBU). If 24VAC is present and the "POWER OK" LED is
off, CB is bad and must be replaced.
3) IS Power Supply: CB supplies 20VDC to IS. Diagnosis: Check that IS green LED is
on. If green LED is not on, check for 20VDC between CB connector K6 dark blue (DBU)
and connector K6 brown (BR). See Fig. 1. If 20VDC is not present, CB is bad and must
be replaced.
Infrared Sensor (20VDC)
Closed
Brown (BR)
20VDC DBU to BR
20VDC DBU to W
0VDC W to BR
Red Positive
Test Lead
20VDC
White (W)
Infrared Sensor (20VDC)
Open (yellow LED flashing or steady)
20VDC DBU to BR
0VDC DBU to W
20VDC W to BR
Dark Blue (DBU)
Black Negative
Test Lead
Multimeter
• K6 Connector
Fig. 1
Infrared Sensor
30
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4) 5VDC Output Checks: Control Switch (open contacts for icemaking, closed contacts
for drain), GMPR (terminals 3 & 5), MBC, and F/S. When checking 5VDC control
voltage, always place the red positive test lead from the multimeter to the white K5
connector pin closest to the red K4 connector. See Fig. 2. Then place the black negative
test lead from the multimeter to the corresponding pin to complete the 5VDC check.
Red positive test lead to white
5VDC
Control Switch
white/black (W/BK)
Black Negative
Test Lead
K5 connector pin closest to
red K4 connecotor
Yellow Jumper (Y)
Red Positive
Test Lead
Multimeter
Gear Motor Protect Relay
(terminals #3 and #5)
white/orange (W/O)
Fig. 2
Control Board K9 Connector
a. Control Switch–K9 connector pins #1 and #2 white/black (W/BK) wires: 5VDC is
present from the white K5 connector pin closest to red K4 connector to the
K9 connector pin #1 white/black (W/BK) wire at all times. If 5VDC is not present,
CB is bad and must be replaced. When the control switch is in the "ICE" position,
the control switch contacts are open. 0VDC is present from the white K5 connector
pin closest to red K4 connector to the K9 connector pin #2 white/black (W/BK) wire.
When in the "ICE" position, 5VDC is present from the K9 connector pin #1 white/
black (W/BK) wire to pin #2 white/black (W/BK) wire. When the control switch is in
the "DRAIN" position, the control switch contacts are closed. 5VDC is present from
the white K5 connector pin closest to red K4 connector to the K9 connector pins
#1 or #2 white/black (W/BK) wires. If 5VDC is not present CB is bad and must be
replaced. 0VDC is present from the K9 connector pin #1 white/black (W/BK) wire to
pin #2 white/black (W/BK) wire.
b. Gear Motor Protect Relay (GMPR)–K9 connector pins #5 and #6 white/orange
(WO) wires: When GMPR terminals 3 and 4 are open (GMPR de-energized), 5VDC
is present from the white K5 connector pin closest to red K4 connector to the K9
connector pin #5 white/orange (W/O) wire. If 5VDC is not present, CB is bad and
must be replaced. When GMPR terminals 3 and 4 are closed (GMPR energized),
5VDC is present from the white K5 connector pin closest to red K4 connector to
the K9 connector pins #5 and #6 white/orange (W/O) wires. Also check from the
K9 connector pin #5 white/orange (W/O) wire to K9 connector pin #6 white/orange
(W/O) wire. If 0VDC is present, GMPR terminals 3 & 5 are closed. If 5VDC is
present, GMPR terminals 3 & 5 are open and CB may be in an 8-beep alarm. See
"II.C.2. LED Lights and Audible Alarm Safeties."
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c. Mechanical Backup Bin Control (MBC) –K8 connector pins #3 and #4 gray (GY)
wires: When MBC is closed (calling for ice), 5VDC is present from the white
K5 connector pin closest to red K4 connector to the K8 connector pin #3 and #4 gray
(GY) wires. Diagnosis: If 5VDC is not present to either pin, CB is bad and must be
replaced. If 5VDC is present to pin #3 gray (GY) wire and not to pin #4 gray (GY)
wire, MBC is open. See "IV.D.2. Mechanical Backup Bin Control Check."
d. Float Switch (LF/S and UF/S) –K8 connector pin #5 black (BK) wire (common),
#6 red (R) wire (upper), and #7 dark blue (DBU) wire (lower): 5VDC is always
present from the white K5 connector pin closest to red K4 connector to the
K8 connector pin #5 black (BK) wire (common). 5VDC is present to the K8 connector
pin #6 red (R) wire (upper) and pin #7 dark blue (DBU) wire (lower) when the F/S
is open. Diagnosis: If 5VDC is not present at K8 connector pin #5 black (BK) wire,
CB is bad and must be replaced. For further F/S diagnostics, see "IV.E. Float Switch
Check and Cleaning."
5) Fill "WTRIN" LED is on: The "WTRIN" LED only turns on when the reservoir water
level is low enough to open the LF/S. The "WTRIN" LED turns off once the UF/S closes.
24VAC is present at CB K2 connector pin #8 to any light blue (LBU) wire when LF/S
is open. Diagnosis: If the LF/S is open and the "WTRIN" LED is off, confirm LF/S
status, open or closed. If LF/S is open and "WTRIN" LED is off, CB is bad and should
be replaced. If "WTRIN" LED is on and 24VAC is not present from CB connector
K2 connector pin #8 to any light blue (LBU) wire, confirm 24VAC from K2 connector pin
#9 to any light blue (LBU) wire. If 24VAC is present on K2 connector pin #9 and not on
K2 connector pin #8, CB is bad and must be replaced.
6) Ice Purge Cycle "GM" LED is on: "GM" LED is on, GM and EH energize.
Diagnosis: If "GM" LED is on and GM and EH are off, check for 115VAC from the
K1 connector pin #2 white/black (BK) wire to a white (W) neutral wire. If 115VAC is not
present, check for 115VAC from CB K1 connector pin #3 brown (BR) wire to a white (W)
neutral wire. If 115VAC is present on pin #3 and not on pin #2, CB is bad and should be
replaced.
7) Freeze Cycle "GM" and "COMP" LED are on: To bypass the Ice Purge Cycle,
press the "SERVICE" button on CB after the "GM" LED turns on. WARNING! Risk of
electric shock. Care should be taken not to touch live terminals. When "COMP"
LED is on 115VAC is present at CB X1 relay dark blue (DBU) wire and PDS energizes.
Diagnosis: Check for 115VAC from CB X1 relay dark blue (DBU) wire to a white neutral
wire. If 115VAC is not present, check X1 relay brown (BR) wire to a white neutral wire.
If 115VAC is present on X1 relay brown (BR) wire and not on X1 relay dark blue (DBU)
wire, CB is bad and must be replaced.
8) Refill "WTRIN" LED is on: See "5) Fill "WTRIN" LED is on:") above.
Legend: CB–control board; EH–evaporator heater; F/S–float switch; GM–gear motor;
GMPR–gear motor protect relay; IS–infrared sensor; LF/S–lower float switch;
MBC–mechanical backup bin control; PDS–pump-down solenoid valve;
UF/S–upper float switch; WV–inlet water valve
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D. Bin Control Check
1. Infrared Sensor Check
IMPORTANT
Make sure S1 dip switch 7 is in the "ON" position. This allows the control board
to monitor the infrared sensor along with the mechanical backup bin control.
1) Remove the front panel.
2) Move the power switch to the "OFF" position, then unplug the unit from the electrical
outlet.
3) Remove the control box cover and access CB. Confirm that S1 dip switch 1, 2, 3 are in
the proper position for your application. See "II.C.3.b) Infrared Sensor Shutdown Delay
(S1 dip switch 1, 2, 3)."
4) Confirm that IS is connected to the K6 connector on CB. Wipe down the IS lens with
a clean, warm, damp cloth. If the bottom of the icemaker is not accessible in your
application, remove the thumbscrew securing the IS housing, then remove the housing
from the base. See Fig. 3.
5) Make sure the control switch is in the "ICE" position, then plug the icemaker into the
electrical outlet.
6) Move the power switch to the "ON" position to start the automatic icemaking process.
Check that the IS green LED is on. The green LED confirms 20VDC power from CB to
IS and remains on constantly. Diagnosis: If the green LED is not on, confirm 20VDC at
K6 connector dark blue (DBU) to brown (BR). If 20VDC is present and the green LED is
off, IS is bad and must be replaced. If not, see step "3) IS Power Supply," under "IV.C.
Control Board Check."
7) Make sure the "GM" LED on CB is on. There is a delay of at least 30 seconds before the
"GM" LED turns on after power-up. After the "GM" LED turns on, press the "SERVICE"
button on CB to bypass the 5-minute ice purge cycle. WARNING! Risk of electric
shock. Care should be taken not to touch live terminals.
8) "GM" and "COMP" LEDs are on. Use an object to cover IS lens. The yellow LED on IS
turns on (flashing or steady). The yellow LED flashes when ice is at the outer limit of its
range and turns steady as ice nears. After the yellow LED turns on (flashing or steady),
IS shutdown delay timer starts . See "II.C.3.b)Infrared Sensor Shutdown Delay (S1 dip
switch 1, 2, 3)." Comp and FMR should de-energize immediately after the shutdown
delay timer terminates. Five minutes later, GM should de-energize. Diagnosis: If the
yellow LED is not on after covering the lens, IS is bad and must be replaced. If the unit
remains on after IS shutdown delay timer terminates and the 5-minute ice purge timer
terminates, CB is bad and must be replaced. If IS fails to shut down the icemaker and
the level of ice activates MBC, the icemaker shuts down within 10 seconds of MBC
opening and a 9-beep alarm sounds. To reset, move the power switch to the "OFF"
position, and then back to the "ON" position.
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9) Remove the object covering IS. If you removed IS housing from the base, replace it in
its correct position, and secure it with the thumbscrew.
10) Move the power switch to the "OFF" position. Unplug the icemaker from the electrical
outlet, then proceed to "IV.D.2. Mechanical Backup Bin Control Check."
Infrared Sensor LED
Infrared Sensor
Thumbscrew
Infrared Sensor LED
Infrared Sensor
Housing
Fig. 3
Lens
2. Mechanical Backup Bin Control Check
When the actuator paddle is not engaged MBC is closed and the icemaker produces ice.
a) Mechanical Backup Bin Control: S1 dip switch 7 placed in the "ON" position, MBC
is used as a backup bin control safety. When ice fills the chute and engages the actuator
paddle, MBC opens and CB shuts down the icemaker within 10 seconds and sounds a
9-beep alarm.
b) Stand-Alone Mechanical Bin Control: S1 dip switch 7 placed in the "OFF" position,
MBC is used as a stand-alone bin control. The stand-alone application should only be
used in Hoshizaki standard ice storage bin applications. WARNING! Do not place S1
dip switch 7 in the "OFF" position on dispenser unit applications. When ice fills the
chute and engages the actuator paddle, MBC opens and CB shuts down the icemaker
within 10 seconds.
1) Remove the front panel.
2) Move the power switch to the "OFF" position, then unplug the unit from the electrical
outlet.
3) Remove the strap connecting the spout to the chute assembly. See Fig. 4. Pull up the
chute assembly slightly so that you can access the actuator paddle located in the top of
the chute.
4) Plug the unit into the electrical outlet.
5) Move the power switch to the "ON" position to start the automatic icemaking process.
Strap
Proximity Switch
Actuator Paddle
Spout
Chute Assembly
Strap
Fig. 4
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6) Make sure the "GM" LED is on. There is a delay of at least 30 seconds before the "GM"
LED turns on after power-up. After the "GM" LED turns on, press the "SERVICE" button
located on CB to bypass the 5-minute ice purge cycle. WARNING! Risk of electric
shock. Care should be taken not to touch live terminals. The "COMP" LED turns
on.
7) Press the actuator paddle located in the top of the chute.
S1 dip switch 7 in the "ON" position: Comp and GM de-energizes within 10 seconds
and CB sounds a 9-beep alarm. S1 dip switch 7 in the "OFF" position: Comp and
GM de-energize within 10 seconds. Diagnosis: If MBC does not open or the icemaker
continues to make ice, check that the actuator paddle is moving freely. Confirm that the
actuator paddle is engaged. Check for continuity across MBC wires. If MBC contacts
are found open and the icemaker continues to make ice, CB is bad and must be
replaced. If MBC is closed with the actuator paddle engaged, MBC is bad and must be
replaced.
8) Move the power switch to the "OFF" position, then unplug the unit from the electrical
outlet.
9) Replace the chute assembly and strap in their correct positions.
10) Replace the control box cover and top panel in their correct positions.
11) Plug the unit into the electrical outlet.
12) Move the power switch to the "ON" position to start the automatic icemaking process.
13) Replace the front panel in its correct position.
Legend: CB–control board; Comp–compressor; GM–gear motor; IS–infrared sensor;
MBC–mechanical backup bin control
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E. Float Switch Check and Cleaning
1. Float Switch Check
1) Remove the front panel, then move the power switch to the "OFF" position.
2) Move the control switch to the "DRAIN" position.
3) Move the power switch to the "ON" position.
4) Allow the water to drain from the evaporator, then move the power switch to the "OFF"
position and the control switch to the "ICE" position.
5) Unplug the unit from the electrical outlet.
6) Remove the control box cover.
7) Remove CB K8 connector and check F/S continuity. Both the UF/S and LF/S should
be open. Check continuity between CB K8 connector pin #5 black (BK) (common) wire
and K8 connector pin #6 red (R) (UF/S) wire. Next, check continuity between CB K8
connector pin #5 black (BK) (common) wire and K8 connector pin #7 dark blue (DBU)
(LF/S) wire. If both are open, continue to step 5. If either are closed, follow the steps in
"IV.E.2. Float Switch Cleaning." After cleaning F/S, check UF/S and LF/S again. Replace
if necessary.
8) Replace CB K8 connector in its correct position.
9) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
and let the water reservoir fill.
10) Once the reservoir is full and GM starts, move the power switch to the "OFF" position.
11) Unplug the unit from the electrical outlet.
12) Remove CB K8 connector and check F/S continuity. Both the UF/S and LF/S should be
closed. Check continuity between CB K8 connector pin #5 black (BK) (common) wire
and K8 connector pin #6 red (R) (UF/S) wire. Next, check continuity between CB K8
connector pin #5 black (BK) (common) wire and K8 connector pin #7 dark blue (DBU)
(LF/S) wire. If either are open, follow the steps in "IV.E.2. Float Switch Cleaning." After
cleaning F/S, check UF/S and LF/S again. Replace if necessary.
13) Replace CB K8 connector in its correct position. Replace the control box cover in its
correct position.
14) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
15) Replace the front panel in its correct position.
2. Float Switch Cleaning
Depending on local water conditions, scale may build up on F/S. Scale on F/S can cause
inconsistant operation of UF/S and LF/S. In this case, both UF/S and LF/S should be
cleaned and checked.
1) Remove the front panel, then move the power switch to the "OFF" position.
2) Unplug the unit from the electrical outlet.
2) Remove F/S assembly from the reservoir cover. See Fig. 5.
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3) Wipe down F/S assembly with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts
warm water. Rinse the assembly thoroughly with clean water.
4) While not necessary, the floats can be removed from the shaft during cleaning. If you
remove them, note that the blue float is on top (UF/S) and the white float is on bottom
(LF/S). The floats must be installed with the magnets inside them towards the top of
the switch. See Fig. 6. Installing the floats upside down will affect the timing of F/S
operation.
5) Rinse the float switch assembly thoroughly with clean water and replace in its correct
position.
6) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
7) Replace the front panel in its correct position.
Legend: CB–control board; F/S–float switch; GM–gear motor; LF/S–lower float switch;
UF/S–upper float switch
Float Switch Assembly
Reservoir Cover
Reservoir
Fig. 5
Red (R)
(upper float switch)
Black (BK)
(common)
Dark Blue (DBU)
(lower float switch)
Magnet (towards top)
Upper Float (blue)
Spring Retainer Clip
Magnet (towards top)
Lower Float (white)
Plastic Retainer Clip
Fig. 6
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F. Diagnostic Charts
Before consulting the diagnostic charts, check for correct installation, proper voltage per unit
nameplate, and adequate water supply. Check CB using the steps in "IV.C. Control Board
Check." Check that the S1 dip switch settings are in the factory default position. For factory
default settings, see "II.C.3.a) Default Dip Switch Settings."
1. No Ice Production
No Ice Production - Possible Cause
Startup
1a. Power Supply-FS
1b. Power Supply-SRC
2. Water Supply
a) Unplugged, off, blown fuse, or tripped breaker.
b) Not within specifications.
a) Off, tripped breaker.
b) Not within specifications.
a) Water supply off or improper water pressure.
b) External water filters clogged.
a) "OFF" position.
3. Power Switch
4. Control Transformer
(115V/24V)
a) Coil winding open or shorted.
5. Fuse (Control Box)
a) Blown.
6. Control Board
a) In alarm.
See "IV.C. Control Board Check"
b) BC OPEN, yellow LED on (bin full).
c) Defective.
7. Control Switch
a) In "DRAIN" position.
b) Bad contacts.
8. Infrared Sensor Bin Control
a) No power, lens dirty, or defective.
b) Control board dip switch 7 off.
9. Mechanical Backup Bin Control a) Tripped with bin filled with ice (9-beep alarm).
b) Proximity switch stuck open.
c) Actuator paddle does not move freely.
Fill Cycle
1. Control Board
a) No power to inlet water valve.
b) No power to float switch or not reading float switch condition.
a) Screen or orifice clogged.
b) Coil winding open.
2. Inlet Water Valve
3. Float Switch
a) Float does not move freely.
b) Defective.
See "IV.E. Float Switch Check
and Cleaning"
Ice Purge Cycle
1. Control Board
2. Gear Motor
a) No power to gear motor.
b) No power to gear motor protect relay circuit.
a) Blown fuse.
b) Internal protector open.
c) Gear motor winding open.
d) Mechanical failure.
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No Ice Production - Possible Cause
Ice Purge Cycle Continued
a) Open windings.
3. Gear Motor Protect Relay
b) Contacts stuck open.
Freeze Cycle
1. Gear Motor Protect Relay
2. Control Board
a) Open.
a) No power to pump-down solenoid valve.
b) X1 relay defective.
3. Pump-Down Solenoid Valve
4. Magnetic Contactor
a) Open coil.
b) Sticking.
a) Open coil.
b) Contacts sticking.
5. Control Low-Pressure Switch
a) Refrigerant pressure too low.
b) Out of adjustment or defective.
a) Refrigerant pressure too low.
b) Defective.
6. Safety Low-Pressure Switch
(manual reset)
7. High-Pressure Switch
a) Dirty condenser.
b) Ambient temperature too warm.
c) Fan motor not operating.
d) Refrigerant overcharged.
e) Bad contacts.
f) Refrigerant lines or components restricted.
a) Magnetic contactor contacts bad or coil winding open.
b) Motor winding open.
c) Bearing worn out or locked rotor.
d) Capacitor defective.
a) Magnetic contactor contacts bad or coil winding open.
b) Motor winding open.
c) Start capacitor or run capacitor defective.
d) Start relay contacts bad or coil winding open.
a) Dirty.
8. Condensing Unit Fan Motor
9. Compressor
10. Evaporator
b) Damaged or defective.
a) Bulb loose.
11. Expansion Valve (TXV)
b) Operating erratically.
a) Low.
12. Refrigerant Charge
13. Drain Valve
a) Dirty, leaking by.
b) Defective coil.
c) Defective control board.
a) Water leaks.
14. Water System
1. Float Switch
Refill
a) Dirty/sticking.
b) Defective.
2. Inlet Water Valve
3. Water Supply
a) Clogged or defective.
a) Off.
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No Ice Production - Possible Cause
4. Control Board
a) No power to float switch or not reading float switch condition.
b) No power to inlet water valve.
Shutdown
1. Infrared Sensor Bin Control
a) Dirty lens.
b) Defective.
c) Control board (no power to IS).
2. Mechanical Backup Bin Control a) Tripped with bin filled with ice (9-beep alarm).
b) Proximity switch stuck closed.
c) Actuator paddle does not move freely.
d) Control board dip switch failure.
3. Pump-Down Solenoid Valve
4. Control Low-Pressure Switch
5. Magnetic Contactor
a) Defective (stuck open).
a) Defective (stuck closed).
a) Contacts stuck closed.
a) No power to IS.
6. Control Board
b) X1 relay defective.
c) In alarm.
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V. Removal and Replacement of Components
WARNING
1. This unit should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
2. Move the power switch to the "OFF" position and unplug the icemaker from
the electrical outlet and turn off the power supply to the condensing unit
before servicing. Lockout/Tagout to prevent the power from being turned back
on inadvertently.
3. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews
are securely in place after the equipment is serviced. Make sure that none
have fallen into the dispenser unit/storage bin.
4. Make sure all food zones in the icemaker and dispenser unit/storage are
clean after the unit is serviced. For cleaning procedures, see "VI. Cleaning
and Maintenance."
5. When replacing evaporator assembly and water circuit components, make
sure there are no water leaks after the repair is complete.
A. Service for Refrigerant Lines
WARNING
1. Repairs requiring the refrigeration circuit to be opened must be performed by
properly trained and EPA-certified service personnel.
2. Always recover the refrigerant and store it in an approved container. Do not
discharge the refrigerant into the atmosphere.
3. Use an electronic leak detector or soap bubbles to check for leaks. Add a
trace of refrigerant to the system (if using an electronic leak detector), and
then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A
as a mixture with pressurized air for leak testing.
CAUTION
1. Do not leave the system open for longer than 15 minutes when replacing or
servicing parts. The Polyol Ester (POE) oils used in R-404A units can absorb
moisture quickly. Therefore it is important to prevent moisture from entering
the system when replacing or servicing parts.
2. Always install a new drier every time the sealed refrigeration system is
opened.
3. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
4. When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
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1. Refrigerant Recovery
The icemaker unit is provided with refrigerant service valves. Using proper refrigerant
practices, recover the refrigerant from the service valves and store it in an approved
container. Do not discharge the refrigerant into the atmosphere.
2. Brazing
WARNING
1. R-404A itself is not flammable at atmospheric pressure and temperatures up
to 176°F (80°C).
2. R-404A itself is not explosive or poisonous. However, when exposed to
high temperatures (open flames), R-404A can be decomposed to form
hydrofluoric acid and carbonyl fluoride both of which are hazardous.
3. Do not use silver alloy or copper alloy containing arsenic.
4. Use an electronic leak detector or soap bubbles to check for leaks. Add a
trace of refrigerant to the system (if using an electronic leak detector), and
then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A
as a mixture with pressurized air for leak testing.
1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
CAUTION
1. Always install a new drier every time the sealed refrigeration system is
opened.
2. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
3. When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
2) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with
pressurized air for leak testing.
3. Evacuation and Recharge (R-404A)
1) Attach a vacuum pump to the system. Be sure to connect charging hoses to both high
and low-side service valves.
IMPORTANT
The vacuum level and vacuum pump may be the same as those for current
refrigerants. However, the rubber hose and gauge manifold to be used for
evacuation and refrigerant charge should be exclusively for POE oils.
2) Turn on the vacuum pump. Open the gauge manifold valves, then open the high and
low-side service valves. Never allow the oil in the vacuum pump to flow backwards.
3) Allow the vacuum pump to pull down to a 29.9" Hg vacuum. Evacuating period depends
on pump capacity.
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4) Close the low-side valve and high-side valve on the gauge manifold.
5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a
refrigerant service cylinder. Remember to loosen the connection and purge the air from
the hose. See the rating label inside the icemaker for the required refrigerant charge.
Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI
Standard 700 (latest edition) be used.
6) A liquid charge is required for charging an R-404A system (to prevent fractionation).
Place the service cylinder on the scales: if the service cylinder is not equipped with
a dip tube, invert the service cylinder, then place it on the scales. Open the high-side
valve on the gauge manifold.
7) Allow the system to charge with liquid until the proper charge weight is met.
8) If necessary, add any remaining charge to the system through the low-side.
CAUTION! To prevent compressor damage, use a throttling valve or liquid
dispensing device to add the remaining liquid charge through the low-side
service valve with the unit running.
9) Close the high and low-side service valves. Close the high and low-side gauge manifold
valves, then disconnect the gauge manifold hoses.
10) Cap the service valves to prevent a possible leak.
B. Important Notes for Component Replacement
CAUTION
When replacing a component listed below, see the notes to help ensure proper
operation.
Component
Notes
Compressor
• Install a new drier, start capacitor, run capacitor, and start relay.
Expansion Valve • Install a new drier.
• Attach the expansion valve bulb to the suction line in the same location as the previous
bulb.
• The bulb should be between the 10 and 2 o'clock positions on the tube.
• Secure the bulb with the clamp and holder, then insulate it.
• Install a new strainer and drier.
Pump-Down
Solenoid Valve
• Use copper tube of the same diameter and length when replacing valve lines.
• Install a new fan motor capacitor.
Fan Motor
Evaporator Assembly Components. See Fig. 7.
Upper and
• Inspect the upper bearing for wear. See "V.B.1. Upper Bearing Wear Check." Replace if
Lower Bearings
necessary.
• When replacing the upper bearing it is advised to also change the lower bearing at the
same time.
Evaporator
Gear Motor
• Install a new drier.
• Inspect the mechanical seal and O-ring prior to installing the new evaporator. If worn,
cracked, or scratched, the mechanical seal should also be replaced.
• Install a new gear motor capacitor.
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Evaporator Assembly
Evaporator Heater
Cutter Hex Head Bolt
Cutter
Washer
Upper Bearing
(pressed into auger)
Extruding Head
Dowel Pin
Auger
O Ring
Seal Bolts and Washers
Seal Bolts and Washers
Socket Head Cap Screw and Split
Lock Washer
Socket Head Cap Screw and Split
Lock Washer
Mechanical Seal
O Ring
Lower Bearing
(pressed into lower housing)
Truss Head Screw
w/Rubber Washer
Lower Housing
Hex Bolt and Washer
Gear Motor Barrier
Gear Motor
Spline Coupling
Socket Head Cap Screw and Split
Lock Washer
Fig. 7
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1. Upper Bearing Wear Check
To ensure that the bearing inside the extruding head does not exceed the wear tolerance
of .02", follow the instructions below.
1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the
unit from the electrical outlet.
2) Remove the top and side panels.
3) Remove the strap connecting the spout to the chute assembly, then remove the spout.
4) Remove the bolt from the auger and lift off the cutter and washer.
5) Replace the bolt in the auger. Grasp the
bolt at the top of the auger and move the
auger towards you and then try to insert a
.02" round stock or pin gauge in between
the back side of the auger shaft and the
bearing surface. Check several locations
around the auger shaft. If the gauge goes
between the shaft and the bearing at
any point or if the bearing is scratched
or cracked, both the top bearing in the
extruding head and the lower bearing in
the lower housing should be replaced.
Instructions for removing the extruding
head and lower housing are located later in
this procedure.
.02" Round Stock
or Pin Gauge
Auger
Extruding
Head
Fig. 8
Note: Replacing the bearing requires a bearing press adaptor. If one is not available,
replace the whole extruding head and lower housing.
6) Remove the bolt. Replace the washer, cutter, and cutter bolt.
7) Replace the spout.
8) Replace the top and side panels in their correct positions.
9) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
10) Replace the front panel in its correct position.
2. Removal and Replacement of Cutter
1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the
unit from the electrical outlet.
2) Remove the top and side panels.
3) Remove the strap connecting the spout to the chute assembly, then remove the spout.
4) Remove the bolt and lift off the cutter.
5) Install the new cutter. Replace the bolt.
6) Replace the spout.
7) Replace the top and side panels in their correct positions.
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8) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
9) Replace the front panel in its correct position.
3. Removal and Replacement of Extruding Head
1) Remove the front panel, then move the power switch to the "OFF" position.
2) Move the control switch to the "DRAIN" position.
3) Move the power switch to the "ON" position.
4) Allow the water to drain from the evaporator.
5) Move the power switch to the "OFF" position, then unplug the unit from the electrical
outlet.
6) Remove the top and side panels.
7) Remove the strap connecting the spout to the chute assembly, then remove the spout.
8) Remove the cutter bolt and lift off the cutter and washer.
9) Remove the seal bolts and lift off the extruding head.
10) Place the new extruding head in place and tighten down the seal bolts.
11) Replace the washer, cutter, cutter bolt, and spout.
12) Replace the top and side panels in their correct positions.
13) Move the control switch to the "ICE" position.
14) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
15) Replace the front panel in its correct position.
4. Removal and Replacement of Auger
1) Remove the front panel, then move the power switch to the "OFF" position.
2) Move the control switch to the "DRAIN" position.
3) Move the power switch to the "ON" position.
4) Allow the water to drain from the evaporator.
5) Move the power switch to the "OFF" position, then unplug the unit from the electrical
outlet.
6) Remove the top and side panels.
7) Remove the strap connecting the spout to the chute assembly, then remove the spout.
8) Remove the extruding head seal bolts. Using the cutter, lift out the auger assembly.
9) Remove the cutter bolt, cutter, washer, and dowel pin. Remove the extruding head from
the auger and place on the new auger.
10) Install the new auger.
11) Replace the removed parts in the reverse order of which they were removed.
12) Replace the top and side panels in their correct positions.
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13) Move the control switch to the "ICE" position.
14) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
15) Replace the front panel in its correct position.
5. Removal and Replacement of Evaporator
CAUTION
1. Always install a new drier every time the sealed refrigeration system is
opened.
2. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
3. When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
1) Remove the front panel, then move the power switch to the "OFF" position.
2) Move the control switch to the "DRAIN" position.
3) Move the power switch to the "ON" position.
4) Allow the water to drain from the evaporator.
5) Move the power switch to the "OFF" position, then unplug the unit from the electrical
outlet.
6) Remove the top and side panels.
7) Recover the refrigerant and store it in an approved container.
8) Remove the strap connecting the spout to the chute assembly, then remove the spout.
9) Disconnect the water hoses.
10) Remove the extruding head seal bolts. Using the cutter, lift out the auger assembly.
11) Remove the insulation and the expansion valve bulb on the suction line.
12) Disconnect the inlet and outlet tubing.
13) Remove the socket head cap screws and split lock washers securing the evaporator to
the lower housing.
14) Lift off the evaporator.
15) Inspect the mechanical seal and O-ring prior to installing the new evaporator. The
mechanical seal consists of two parts. One moves along with the auger, and the other
is fixed on the lower housing. If the contact surfaces of these two parts are worn,
cracked, or scratched, the mechanical seal may cause water leaks and should be
replaced. Instructions for removing the mechanical seal and lower housing are located
later in this procedure.
16) Make sure the lower mechanical seal is in place, then place the evaporator in position.
Secure the evaporator to the lower housing using the socket head cap screws and split
lock washers.
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17) Remove the drier, then place the new drier in position.
18) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
19) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). Do Not use R-404A as a mixture with
pressurized air for leak testing.
20) Evacuate the system, and charge it with refrigerant. See the rating label inside the
icemaker for the required refrigerant charge. Hoshizaki recommends only virgin
refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be
used.
21) Replace the removed parts in the reverse order of which they were removed.
22) Replace the top and side panels in their correct positions.
23) Move the control switch to the "ICE" position.
24) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
25) Replace the front panel in its correct position.
6. Removal and Replacement of Mechanical Seal and Lower Housing
6a. Mechanical Seal
1) Remove the front panel, then move the power switch to the "OFF" position.
2) Move the control switch to the "DRAIN" position.
3) Move the power switch to the "ON" position.
4) Allow the water to drain from the evaporator.
5) Move the power switch to the "OFF" position, then unplug the unit from the electrical
outlet.
6) Remove the top and side panels.
7) Remove the strap connecting the spout to the chute assembly, then remove the spout.
8) Remove the extruding head seal bolts. Using the cutter, lift out the auger assembly.
9) The mechanical seal consists of two parts. One moves along with the auger, and the
other is fixed on the lower housing. If the contact surfaces of these two parts are worn,
cracked, or scratched, the mechanical seal may cause water leaks and should be
replaced.
10) Remove the socket head cap screws and split lock washers securing the evaporator to
the lower housing.
11) Raise the evaporator up to access the lower housing.
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12) Remove the O-ring and mechanical seal from the housing. If only replacing the
mechanical seal, proceed to step 15.
WARNING
To help prevent water leaks, be careful not to damage the surfaces of the
O-ring or mechanical seal.
6b. Lower Housing
13) Remove the hex bolts w/washers securing the lower housing to the gear motor and
remove the lower housing from the gear motor. If inspection of the upper bearing inside
the extruding head (see "V.B.1. Upper Bearing Wear Check") indicates that it is out of
tolerance, replace both it and the bearing inside the lower housing.
Note: Replacing the bearing requires a bearing press adaptor. If one is not available,
replace the whole extruding head and lower housing.
14) Mount the lower housing on the gear motor.
15) Install the O-ring and lower part of the mechanical seal on the lower housing.
16 ) Make sure the lower mechanical seal is in place, then place the evaporator in position.
Secure the evaporator to the lower housing using the socket head cap screws and split
lock washers.
17) Install the auger assembly with the upper part of the mechanical seal attached.
18) Replace the removed parts in the reverse order of which they were removed.
19) Replace the top and side panels in their correct positions.
20) Move the control switch to the "ICE" position.
21) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
22) Replace the front panel in its correct position.
7. Removal and Replacement of Gear Motor
1) Remove the front panel, then move the power switch to the "OFF" position.
2) Move the control switch to the "DRAIN" position.
3) Move the power switch to the "ON" position.
4) Allow the water to drain from the evaporator.
5) Move the power switch to the "OFF" position, then unplug the unit from the electrical
outlet.
6) Remove the top and side panels.
7) Remove the strap connecting the spout to the chute assembly, then remove the spout.
8) Remove the hex head bolts and washers securing the lower housing to the gear motor.
Lift the evaporator up slightly.
9) Remove the socket head cap screws with split lock washers securing the gear motor.
10) Disconnect the gear motor wiring, then remove the gear motor.
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11) Remove the gear motor bracket and spline coupling from the old gear motor and place
on the new gear motor.
12) Install the new gear motor and reconnect the electrical wires.
13) Replace the removed parts in the reverse order of which they were removed.
14) Replace the top and side panels in their correct positions.
15) Move the control switch to the "ICE" position.
16) Plug the unit into the electrical outlet, then move the power switch to the "ON" position
to start the automatic icemaking process.
17) Replace the front panel in its correct position.
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VI. Cleaning and Maintenance
This icemaker must be cleaned and maintained in accordance with the instruction
manual and labels provided with the icemaker. Consult with your local distributor
about cleaning and maintenance service. To obtain the name and phone number of
1-800-233-1940 in the USA.
WARNING
1. Only qualified service technicians should attempt to service this icemaker.
2. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews
are securely in place after any cleaning or maintenance is done to the unit.
Make sure that none have fallen into the dispenser unit/storage bin.
3. The dispenser unit/storage bin is for ice use only. Do not store anything else
in the dispenser unit/storage bin.
A. Cleaning and Sanitizing Instructions
Hoshizaki recommends cleaning and sanitizing this icemaker at least twice a year. More
frequent cleaning and sanitizing, however, may be required in some existing water
conditions.
WARNING
1. To prevent injury to individuals and damage to the icemaker, do not use
ammonia type cleaners.
2. Carefully follow any instructions provided with the bottles of cleaning and
sanitizing solution.
3. Always wear liquid-proof gloves and goggles to prevent the cleaning and
sanitizing solutions from coming into contact with skin or eyes.
4. After cleaning and sanitizing, do not use ice made from the cleaning and
sanitizing solutions. Be careful not to leave any solution on the parts or in the
dispenser unit/storage bin.
1. Cleaning Solution
IMPORTANT
For safety and maximum effectiveness, use the solution immediately after
dilution.
Dilute 9.6 fl. oz. (0.29 l) of Hoshizaki "Scale Away" with 1.6 gal. (6.0 l) of warm water.
2. Cleaning Procedure
1) Remove the front panel, then move the power switch to the "OFF" position. Move the
control switch to the "DRAIN" position, then move the power switch back to the "ON"
position. Replace the front panel in its correct position.
2) Close the water supply line shut-off valve.
3) Allow the water system to drain for 5 minutes.
4) Remove the front panel. Move the power switch to the "OFF" position, then unplug the
unit from the electrical outlet. Remove the top panel.
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5) Remove all of the ice from the dispenser unit/storage bin.
6) Remove the strap connecting the spout to the chute assembly, then remove the spout.
See Fig. 9.
Plate
Packing
Proximity Switch
Strap
Backup Bin Control Assembly Mount
Chute
Bracket
Shaft
Actuator
Packing
Spout
Baffle
Rubber O-Ring
Nylon O-Ring
Float Switch
Assembly
Ties
Reservoir Cover
Extruding Head
(Hook and Loop)
Reservoir
Reservoir
Hose
Evaporator Assembly
Chute Insulation
Chute
Packing
Fig. 9
Infrared Sensor Lens
7) Pour the cleaning solution over the extruding head until the evaporator assembly and
the reservoir are full and the solution starts to overflow into the drain pan.
Note: If there is excess scale on the extruding head, fill the evaporator assembly and
reservoir as described above, then use a clamp on the reservoir hose between
the reservoir and evaporator assembly to block flow. Pour additional cleaning
solution over the extruding head until the evaporator assembly is completely full.
8) Replace the spout and strap in their correct positions.
9) Allow the icemaker to sit for about 10 minutes before operation. If you placed a clamp on
the reservoir hose in step 7, remove it before operation.
10) In bad or severe water conditions, clean the float switch assembly as described below.
Otherwise, continue to step 11.
a. Remove the float switch assembly from the reservoir cover.
b. Wipe down the float switch assembly with the cleaning solution.
c. Rinse the float switch assembly thoroughly with clean water.
d. Replace the float switch assembly in its correct position.
Float Switch Assembly
Reservoir Cover
Reservoir
Fig. 10
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11) Wipe down the infrared sensor lens, (located on the bottom of the icemaker) with the
cleaning solution. Next, rinse the cleaning solution off of the infrared sensor lens with a
clean, damp cloth.
Infrared Sensor
Infrared Sensor
Housing
Fig. 14
Lens
12) Replace the top panel in its correct position. Move the control switch to the "ICE"
position, then plug the unit back in. Move the power switch to the "ON" position, then
replace the front panel in its correct position. Make ice using the solution until the
icemaker stops making ice.
13) Remove the front panel, then move the power switch to the "OFF" position. Move the
control switch to the "DRAIN" position, then move the power switch back to the "ON"
position. Replace the front panel in its correct position.
14) Allow the water system to drain for 5 minutes.
15) Remove the front panel. Move the control switch to the "ICE" position, then replace the
front panel in its correct position.
16) Open the water supply line shut-off valve to supply water to the reservoir.
17) After the gear motor starts, remove the front panel. Move the power switch to the "OFF"
position. Move the control switch to the "DRAIN" position, then move the power switch
back to the "ON" position. Replace the front panel in its correct position.
18) Allow the water system to drain for 5 minutes.
Note: If you do not sanitize the unit, go to step 14 in "III.A.5. Sanitizing
Procedure - Final."
19) Remove the front panel. Move the power switch to the "OFF" position, then unplug the
unit from the electrical outlet. Close the water supply line shut-off valve.
3. Sanitizing Solution
IMPORTANT
For safety and maximum effectiveness, use the solution immediately after
dilution.
Dilute 2.5 fl. oz. (74 ml or 5 tbs) of a 5.25% sodium hypochlorite solution (chlorine bleach)
with 5 gal. (19 l) of warm water.
4. Sanitizing Procedure - Initial
1) Make sure the power switch is in the "OFF" position, the unit is unplugged from the
electrical outlet, and the water supply line shut-off valve is closed. Remove the panels.
2) Remove the strap connecting the spout to the chute assembly, then remove the spout.
Remove the rubber O-ring and nylon O-ring at the top of the cylinder and also remove
the packing and chute bracket between the spout and chute.
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3) Pour the sanitizing solution over the extruding head until the evaporator assembly and
the reservoir are full and the solution starts to overflow into the drain pan.
4) Remove the proximity switch from the chute assembly, then remove the chute assembly
from the icemaker.
5) Remove the packing at the bottom of the ice chute. Remove the 3 ties and the chute
insulation.
6) Remove the 2 baffles.
7) Remove the plate and the packing from the top of the ice chute, then remove the
backup bin control assembly by sliding it slightly towards the chute opening and lifting it
off.
8) Disassemble the backup bin control assembly by removing the 2 snap pins, shaft, and
actuator.
9) Soak the spout, O-ring, packings, chute, baffles, plate, and backup bin control assembly
in the sanitizing solution for 10 minutes then wipe them down.
10) Rinse the parts thoroughly with clean water.
CAUTION
If the solution is left on these parts, they will rust.
11) Replace all parts in their correct positions.
IMPORTANT
When installing the baffles, make sure that the bent surface (the one without
the studs) faces the actuator so that the bent surface can guide the ice to the
center of the actuator.
12) Replace all panels except the front panel in their correct positions. Move the control
switch to the "ICE" position, then plug the unit back in. Move the power switch to the
"ON" position, then replace the front panel in its correct position. Make ice using the
solution until the icemaker stops making ice.
13) Remove the front panel, then move the power switch to the "OFF" position. Move the
control switch to the "DRAIN" position, then move the power switch back to the "ON"
position. Replace the front panel in its correct position.
14) Allow the water system to drain for 5 minutes.
15) Remove the front panel. Move the power switch to the "OFF" position, then unplug the
unit from the electrical outlet.
5. Sanitizing Procedure - Final
1) Mix a new batch of the sanitizing solution.
2) Make sure the power switch is in the "OFF" position, the unit is unplugged from the
electrical outlet, and the water supply line shut-off valve is closed. Remove the top
panel.
3) Remove the strap connecting the spout to the chute assembly, then remove the spout.
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4) Pour the sanitizing solution over the extruding head until the evaporator assembly and
the reservoir are full and the solution starts to overflow into the drain pan.
5) Replace the spout and strap in their correct positions.
6) Allow the icemaker to sit for about 10 minutes before operation.
7) Replace the top panel in its correct position. Move the control switch to the "ICE"
position, then plug the unit back in. Move the power switch to the "ON" position, then
replace the front panel in its correct position. Make ice using the solution until the
icemaker stops making ice.
8) Remove the front panel, then move the power switch to the "OFF" position. Move the
control switch to the "DRAIN" position, then move the power switch back to the "ON"
position. Replace the front panel in its correct position.
9) Allow the water system to drain for 5 minutes.
10) Remove the front panel. Move the control switch to the "ICE" position, then replace the
front panel in its correct position.
11) Open the water supply line shut-off valve to supply water to the reservoir.
12) After the gear motor starts, remove the front panel. Move the power switch to the "OFF"
position. Move the control switch to the "DRAIN" position, then move the power switch
back to the "ON" position. Replace the front panel in its correct position.
13) Allow the water system to drain for 5 minutes.
14) Remove the front panel. Move the control switch to the "ICE" position, then replace the
front panel in its correct position.
15) Allow the icemaker to run for about 30 minutes, then remove the front panel. Move the
power switch to the "OFF" position, then unplug the unit from the electrical outlet.
16) Pour warm water into the dispenser unit/storage bin and melt any remaining ice. Clean
the dispenser unit/storage bin liner using a neutral cleaner. Rinse thoroughly after
cleaning.
17) Plug the unit back in. Make sure the control switch is in the "ICE" position, then move
the power switch to the "ON" position to start the automatic icemaking process.
B. Maintenance
This icemaker must be maintained individually, referring to the instruction manual and
labels provided with the icemaker. The schedule below is a guideline. More frequent
maintenance, however, may be required depending on water quality, the icemaker's
environment, and local sanitation regulations.
Consult with your local distributor about inspection and maintenance service. To obtain
Hoshizaki Technical Support at 1-800-233-1940 in the USA.
WARNING
1. Only qualified service technicians should attempt to service this icemaker.
2. Move the power switch to the "OFF" position and unplug the unit from the
electrical outlet before servicing.
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Maintenance Schedule
Frequency Area
Task
Monthly
External Water
Check for proper pressure and change if necessary.
Filters
Icemaker and
Dispenser Unit/
Storage Bin
Exterior
Wipe down with clean, soft cloth. Use a damp cloth containing a neutral
cleaner to wipe off oil or dirt build up. Clean any chlorine staining (rust
colored spots) using a non-abrasive cleaner like Zud or Bon Ami.
Infrared Sensor
Wipe down with clean cloth and warm water.
Lens; Underside of
Icemaker and Top
Kits; Bin Door and
Snout (if applicable)
Every 6
Months
Icemaker and
Dispenser Unit/
Storage Bin
Clean and sanitize per the cleaning and sanitizing instructions provided in
this manual.
Evaporator
Wipe down with clean cloth and warm water. Slowly pour one cup of
Condensate Drain sanitizing solution (prepare as outlined in the sanitizing instructions in
Pan and Gear
Motor Drain Pan
this manual) into the evaporator condensate drain pan. Be careful not to
overflow the pan. This solution will flow down to the gear motor drain pan
and out the drain line to sanitize these areas. Repeat with a cup of clean
water to rinse.
Icemaker and
Check to make sure they are clear.
Dispenser Unit/
Storage Bin Drains
Yearly
Inlet Water Valve
and Drain Valve
Close the water supply line shut-off valve and drain the water system. Clean
the inlet water valve screen and clean and inspect the drain valve.
Water Hoses
Condenser
Icemaker
Inspect the water hoses and clean/replace if necessary.
Inspect. Clean if necessary by using a brush or vacuum cleaner.
Inspect for oil spots, loose components, fasteners, and wires.
Upper Bearing
(extruding head)
Check for wear using .02" round stock or pin gauge. Replace both upper
bearing and lower bearing if wear exceeds factory recommendations. See
the Service Manual for details.
After
3 Years,
then Yearly Lower Bearing
and O-Ring
Upper Bearing
(extruding head);
Inspect. Replace both upper bearing and lower bearing if wear exceeds
factory recommendations. Replace the mechanical seal if the seal's contact
surfaces are worn, cracked, or scratched.
(lower housing);
Mechanical
Seal; Evaporator
Cylinder; Auger
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C. Preparing the Icemaker for Long Storage
CAUTION
When storing the icemaker for an extended time or in sub-freezing
temperatures, follow the instructions below to prevent damage.
When the icemaker is not used for two or three days under normal conditions, it is
sufficient to only move the power switch to the "OFF" position. When storing the icemaker
for extended time or in sub-freezing temperatures, follow the instructions below.
1. Remove the water from the icemaker water supply line:
1) Remove the front panel.
2) Move the power switch to the "OFF" position.
3) Close the icemaker water supply line shut-off valve, then open the icemaker water
supply line drain valve.
4) Allow the line to drain by gravity.
5) Attach a compressed air or carbon dioxide supply to the icemaker water supply line
drain valve.
6) Move the control switch to the "ICE" position, then move the power switch to the "ON"
position.
7) Blow the icemaker water line out using the compressed air or carbon dioxide supply.
8) Close the icemaker water supply line drain valve.
2. Drain the evaporator:
1) Move the power switch to the "OFF" position. Move the control switch to the "DRAIN"
position, then move the power switch back to the "ON" position. Replace the front panel
in its correct position.
2) Allow the water system to drain for 5 minutes.
3) Remove the front panel, then move the power switch to the "OFF" position.
4) Remove the evaporator drain line hose from the evaporator and attach a compressed
air or carbon dioxide supply to the hose.
5) Move the power switch to the "ON" position. Blow out the evaporator drain line using the
compressed air or carbon dioxide supply until water stops coming out.
6) Move the power switch to the "OFF" position, then reconnect the evaporator drain line
hose.
7) Move the control switch to the "ICE" position. Replace the front panel in its correct
position, then unplug the unit from the electrical outlet.
8) Remove all ice from the dispenser unit/storage bin. Clean the dispenser unit/storage bin
liner using a neutral cleaner. Rinse thoroughly after cleaning.
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