Hoshizaki C-100BAF-AD, C-100BAF-ADDS User Manual

Hoshizaki America, Inc.

Hoshizaki

Self-Contained Cubelet

Models
C-100BAF-AD

“A Superior Degree

of Reliability”

www.hoshizaki.com

C-100BAF-ADDS

SERVICE MANUAL

Number: 73180
Issued: 10-6-2010

IMPORTANT

Only qualied service technicians should install, service, and maintain the
icemaker. No service or maintenance should be undertaken until the technician
has thoroughly read this Service Manual. Failure to service and maintain
the equipment in accordance with this manual may adversely affect safety,
performance, component life, and warranty coverage.

Hoshizaki provides this manual primarily to assist qualied service technicians in the
service and maintenance of the icemaker.

Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call, write, or send an e-mail message to the Hoshizaki Technical
Support Department for assistance.

HOSHIZAKI AMERICA, INC.
618 Highway 74 South
Peachtree City, GA 30269

Attn: Hoshizaki Technical Support Department

Phone: [phone] Technical Support
[phone]
Fax: [phone]
[phone]
E-mail: [e-mail]

Web Site: www.hoshizaki.com

NOTE: To expedite assistance, all correspondence/communication MUST include the

following information:

• Model Number ________________________

• Serial Number ________________________

• Complete and detailed explanation of the problem.

2

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 Indicates a situation which could result in damage to the unit.

IMPORTANT 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 re, follow
basic precautions including the following:

• This unit requires an independent power supply. See the nameplate for proper
voltage and breaker/fuse size. Failure to use a proper breaker or fuse can
result in a tripped breaker, blown fuse, or damage to existing wiring. This
could lead to heat generation or re.

• THIS APPLIANCE 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 qualied 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.

• Make sure the power switch is in the "OFF" position before plugging in or
unplugging the unit to reduce the risk of electric shock.

• 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 re. To unplug the unit, be sure to pull the
plug, not the cord, and do not jerk the cord.

• To reduce the risk of electric shock, do not touch the plug or power switch with
damp hands.

• Do not place ngers or any other objects into the ice discharge opening.

• This unit should be disassembled or repaired only by qualied service
personnel to reduce the risk of electric shock, injury, or re.

• Do not make any alterations to the unit. Alterations could result in electric
shock, injury, re, or damage to the unit.

3

IMPORTANT

This manual should be read carefully before the icemaker is serviced or
maintenance operations are performed. Only qualied 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 ................................................................................................. 3

I. Specications ...................................................................................................................... 6

II. General Information ........................................................................................................... 7

A. Construction .................................................................................................................. 7

1. Icemaker .................................................................................................................. 7

2. Ice Making Unit ........................................................................................................ 8

B. Sequence of Operation ................................................................................................. 9

1. Freeze Cycle ............................................................................................................ 9

2. Bin Control Thermostat Shutdown ........................................................................... 9

III. Technical Information ...................................................................................................... 10

A. Water Circuit and Refrigeration Circuit ........................................................................ 10

B. Wiring Diagram .............................................................................................................11

1. C-100BAF Series ....................................................................................................11

2. C-100BAF Series with Optional Drain Pump HS-0248 ...........................................11

3. Sequence Wiring Diagram ..................................................................................... 12

a) Freeze Cycle ....................................................................................................... 12

b) Bin Control Thermostat Shutdown ...................................................................... 13

c) Low Water/Freeze-Up Safety Shutdown ............................................................. 14

d) Gear Motor Protector (external overload) Shutdown .......................................... 15

e) Optional Drain Pump HS-0248 Safety Shutdown ............................................... 16

C. Performance Data ....................................................................................................... 17

IV. Service Diagnosis ........................................................................................................... 18

A. Ice Production Check .................................................................................................. 18

B. Diagnostic Procedure .................................................................................................. 18

C. Diagnostic Charts ....................................................................................................... 20

1. No Ice Production ................................................................................................... 20

2. Low Ice Production ................................................................................................ 22

3. Other ...................................................................................................................... 23

D. Optional Drain Pump HS-0248 .................................................................................... 24

1. Overview ................................................................................................................ 24

2. Float Switch Cleaning ............................................................................................ 24

V. Removal and Replacement of Components .................................................................... 26

A. Service for Refrigerant Lines ....................................................................................... 26

1. Refrigerant Recovery ............................................................................................. 26

2. Brazing .................................................................................................................. 27

3. Evacuation and Recharge (R-134a) ...................................................................... 27

B. Removal and Replacement of Compressor ................................................................. 28

4

C. Removal and Replacement of Evaporator Assembly Components ............................. 30

1. Upper Bearing Wear Check .................................................................................. 31

2. Removal and Replacement of Extruding Head ...................................................... 32

3. Removal and Replacement of Auger ..................................................................... 32

4. Removal and Replacement of Evaporator ............................................................. 33

5. Removal and Replacement of Mechanical Seal and Lower Housing ................... 35

6. Removal and Replacement of Gear Motor ............................................................ 36

D. Removal and Replacement of Fan Motor .................................................................... 36

E. Removal and Replacement of Water Reservoir .......................................................... 37

F. Removal and Replacement of Bin Control Thermostat Assembly ................................ 37

VI. Cleaning and Maintenance ............................................................................................. 38

A. Cleaning and Sanitizing Instructions ........................................................................... 38

1. Cleaning Solution ................................................................................................... 38

2. Cleaning Procedure ............................................................................................... 38

3. Sanitizing Solution ................................................................................................. 40

4. Sanitizing Procedure - Initial .................................................................................. 40

5. Sanitizing Procedure - Final ................................................................................... 41

B. Maintenance ................................................................................................................ 42

C. Preparing the Icemaker for Long Storage ................................................................... 44

5

I. Specications

A

A

)

A

A. C-100BAF-AD, C-100BAF-ADDS

AC SUPPLY VOLTAGE 115/60/1
AMPERAGE 4.0 A
MINIMUM CIRCUIT AMPACITY 15 A
MAXIMUM FUSE SIZE 15 A

PPROXIMATE ICE PRODUCTION

PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day

Reference without *marks 80 81 (37) 71 (32) 66 (30)

SHAPE OF ICE Cubelet
ICE QUALITY Approx. 90%

PPROXIMATE STORAGE CAPACITY 29 lbs. (13 kg) [Bin Control Setting 22 lbs. (10.0 kg)]

ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 310 (12.1) 297 (7.7)

WATER gal./24HR (gal./100 lbs.) 7.7 (12) 11.1 (12)
EXTERIOR DIMENSIONS (WxDxH) 14.9" x 22.6" x 31.5" (378 x 575 x 800mm)
EXTERIOR FINISH Stainless steel, Galvanized Steel (Rear)
WEIGHT Net 104 lbs. ( 47 kg ), Shipping 115 lbs. (52 kg) without pallet
CONNECTIONS - ELECTRIC Cord Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 1/2" FPT
ICE MAKING SYSTEM Auger type
HARVESTING SYSTEM Direct Drive Auger (80W Gear Motor)
ICE MAKING WATER CONTROL Mechanical float valve
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Thermostat
COMPRESSOR Hermetic, Model QA51K13GAU6
CONDENSER
EVAPORATOR Copper Tube on Cylinder
REFRIGERANT CONTROL Capillary Tube
REFRIGERANT CHARGE R134a 3.17 oz. (90 g)
DESIGN PRESSURE High 240 PSIG, Low 120 PSIG
P.C. BOARD CIRCUIT PROTECTION N/A
COMPRESSOR PROTECTION Auto-reset Overload Protector
GEAR MOTOR PROTECTION Manual reset Circuit Breaker
LOW WATER PROTECTION Suction Temperature Safety
ACCESSORIES - SUPPLIED Ice Scoop; pump adapter hose

- REQUIRED N/A
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V

AGENCY UL OUTDOOR APPROVED, cUL

mbient WATER TEMP. (°F)

70 *92 (42) 89 (40) 84 (38)

90 66 (30) *62 (28) 57 (26)
100 55 (25) 54 (24) *49 (22)

Air-cooled, Fin and tube type

AMBIENT TEMP. 45 - 100° F
WATER SUPPLY TEMP. 45 - 90° F
WATER SUPPLY PRESSURE 7 - 113 PSIG

ETL

Note: We reserve the right to make changes in specications and design without prior

notice.

6

II. General Information

A. Construction

1. Icemaker

Ice Discharge Opening

Bin Control
Thermostat Bulb

Slope

Air-Cooled Condenser and
Condenser Fan Motor

Gear Motor Protector (External Overload) Reset Switch

Control Box

Power Switch

Front Panel

Louver

Bin Control Thermostat

Float-Operated Water Valve

Water Reservoir

Suction Temperature Safety

Upper Rear Panel

Lower Rear Panel

Front

C-100BAF-AD Shown

Top Panel

Evaporator Assembly

Gear Motor

Compressor

Drier

Rear

C-100BAF-AD Shown

7

Fig. 1

2. Ice Making Unit

Cutter (motionless)

Allen Head Cap Screw

Extruding Head
and Upper
Bearing

Auger

Cylinder

Mechanical Seal

O-Ring

Evaporator Flange

Insulation

Gear Motor

Housing and
Lower Bearing

Spline Coupling

Hex Head
Bolt with
Washer

Allen Head
Cap Screw
with Washer

Fig. 2

8

B. Sequence of Operation

This icemaker utilizes a thermostatic bin control to switch the gear motor, fan motor, and
compressor on and off as needed. This icemaker utilizes a oat-operated water valve in
the water reservoir to allow water into the icemaker as needed. After the power switch is
placed in the "ON" position, the sequence is as follows:

1. Freeze Cycle

GM, FM, CR, and Comp energize. As the 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.
The oat-operated water valve allows water into the reservoir as needed to continue the
ice making process. This continues until BC shuts down the icemaker or power is turned
off to the icemaker.

2. Bin Control Thermostat Shutdown

Ice lls storage bin to level of BC. When BC opens, GM, FM, CR, and Comp de-energize.
When ice level lowers and BC closes, the icemaker starts operating again.

C-100BAF Series Sequence Flow Chart and Component Operation

BC closed

Power Switch
"ON"

BC closed
GM energized
FM energized
CR energized
Comp energized

1. Freeze Cycle

The oat-operated water valve allows
water into the reservoir as needed to
continue the ice making process.

BC closed
GM continues
FM continues
CR continues
Comp continues

When BC opens, the icemaker shuts
down. When BC closes, the icemaker
starts operating again.

2. Shutdown

Full Bin

BC open

BC open
GM de-energized
FM de-energized
CR de-energized
Comp de-energized

Legend: BC–bin control thermostat; Comp–compressor; CR–compressor relay;

FM–fan motor; GM–gear motor

9

III. Technical Information

A. Water Circuit and Refrigeration Circuit

1. C-100BAF Series

Float-Operated

Water Inlet

Water Valve

Water
Reservoir

Overow Hose

Water Level

Evaporator
Assembly

Water Supply

Drier

Gear
Motor

Capillary Tube

Condenser

Condenser
Fan Motor

Discharge

Compressor

10

Suction
Temperature
Safety

Fig. 3

Suction

B. Wiring Diagram

1. C-100BAF Series

(3W)

(external)

(external
overload

2.4~3.0A)

(internal)

2. C-100BAF Series with Optional Drain Pump HS-0248

(3W)

(external)

(internal)

(external
overload

2.4~3.0A)

11

3. Sequence Wiring Diagram

a) Freeze Cycle

Power supplied. Gear motor, fan motor, compressor relay, and compressor energize. The
oat-operated water valve allows water into the reservoir as needed to continue the ice
making process.

(external
overload

2.4~3.0A)

(3W)

(internal)

(external)

12

C-100BAF Series

b) Bin Control Thermostat Shutdown

Ice lls storage bin to level of bin control thermostat. Bin control thermostat opens. Gear
motor, fan motor, compressor relay, and compressor de-energize.

(external
overload

2.4~3.0A)

(3W)

(internal)

(external)

13

C-100BAF Series

c) Low Water/Freeze-Up Safety Shutdown

If the water supply is interrupted or a freeze-up condition occurs, the decrease in suction
line temperature causes the suction temperature safety to open and shut down the
icemaker. See the table below for suction temperature safety cut-out/cut-in temperatures.

Suction Temperature Safety

Cut-out 23.9°F±2.7°F (-4.5°C±1.5°C)
Cut-in 29.0°F±2.7°F (-1.5°C±1.5°C)

(external
overload

2.4~3.0A)

(3W)

(internal)

(external)

14

C-100BAF Series