Hoshizaki F-300BAF User Manual

Hoshizaki

“A Superior Degree

of Reliability”

www.hoshizaki.com

Model
F-300BAF

Self-Contained Flaker

Hoshizaki America, Inc.

Number: 73072
Issued: 3-2-1999
Revised: 01-25-2007

SERVICE MANUAL

IMPORTANT

Only qualified service technicians should attempt to service or maintain this
unit. No such service or maintenance should be undertaken until the technician
has thoroughly read this Service Manual.

HOSHIZAKI provides this manual primarily to assist qualified service technicians in the
service and maintenance of the unit.

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 Service
[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

Please review this manual. It should be read carefully before the unit is serviced or
maintenance operations are performed. Only qualified service technicians should service
and maintain the unit. This manual should be made available to the technician prior to
service or maintenance.

CONTENTS

I. Specifications ...................................................................................................................... 5

A. Icemaker ....................................................................................................................... 5

II. General Information ........................................................................................................... 6

A. Construction .................................................................................................................. 6

B. Ice Making Unit ............................................................................................................. 7

C. Control Box Layout ........................................................................................................ 8

a) Auxiliary Code K-1 and Earlier ............................................................................. 8

b) Auxiliary Code K-2 and L-0 .................................................................................. 8

c) Auxiliary Code L-1 and M-0 .................................................................................. 9

d) Auxiliary Code M-1 and Later ............................................................................... 9

D. Timer Board ................................................................................................................. 10

1. Solid-State Timer Board Control ............................................................................ 10

E. Sequence of Operation ............................................................................................... 11

1. Startup ................................................................................................................... 11

2. Fill Cycle ................................................................................................................ 11

3. Ice Purge Cycle (60 seconds) ............................................................................... 11

4. Freeze Cycle (Ice Making Process) ....................................................................... 11

5. Shutdown: ............................................................................................................. 11

F. Ice Production Check ................................................................................................... 11

III. Technical Information ...................................................................................................... 13

A. Water Circuit and Refrigeration Circuit ........................................................................ 13

B. Wiring Diagram ............................................................................................................ 14

1. Auxiliary Code K-1 and Earlier .............................................................................. 14

2. Auxiliary Code K-2 and L-0 ....................................................................................

3. Auxiliary Code L-1 and M-0 ................................................................................... 16

4. Auxiliary Code M-1 and Later ................................................................................ 17

C. Sequence of Electrical Circuit ..................................................................................... 18

1. Fill Cycle ............................................................................................................... 18

2. Ice Purge Cycle ....................................................................................................

3. Freeze Cycle ......................................................................................................... 20

4. Shutdown .............................................................................................................. 21

5. Cleaning - Flush Switch ........................................................................................ 22

6. Low Water Safety ................................................................................................... 23

7. Spout Safety Switch .............................................................................................. 24

8. High Pressure Switch ............................................................................................ 25

D. Performance Data ....................................................................................................... 26

IV. Service Diagnosis ........................................................................................................... 27

A. Diagnostic Procedure .................................................................................................. 27

B. Diagnostic Charts ........................................................................................................ 29

1. No Ice Production .................................................................................................. 29

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

3. Other ...................................................................................................................... 32

15

19

31

3

V. Removal and Replacement of Components .................................................................... 33

A. Service for Refrigerant Lines ...................................................................................... 33

1. Refrigerant Recovery ............................................................................................ 33

2. Evacuation and Recharge [R-404A] ...................................................................... 33

B. Brazing ........................................................................................................................ 34

C. Removal and Replacement of Compressor ................................................................ 35

D. Removal and Replacement of Drier ............................................................................ 36

E. Removal and Replacement of Expansion Valve .......................................................... 36

F. Removal and Replacement of Evaporator Assembly Components ............................. 38

1. Upper Bearing Wear Check ..................................................................... 39

2. Removal and Replacement of Cutter..................................................................... 39

3. Removal and Replacement of Extruding Head ..................................................... 40

4. Removal and Replacement of Auger ..................................................................... 40

5. Removal and Replacement of Evaporator ............................................................. 40

6. Removal and Replacement of Mechanical Seal and Lower Housing ................... 41

7. Removal and Replacement of Gear Motor ............................................................ 42

G. Removal and Replacement of Fan Motor ................................................................... 43

H. Removal and Replacement of Inlet Water Valve ......................................................... 43

I. Removal and Replacement of Flush Water Valve ......................................................... 43

VI. Cleaning and Maintenance ............................................................................................. 45

A. Cleaning and Sanitizing Instructions ........................................................................... 45

1. Cleaning Solution .................................................................................................. 45

2. Cleaning Procedure ............................................................................................... 45

3. Sanitizing Solution ................................................................................................. 46

4. Sanitizing Procedure - Initial .................................................................................. 47

5. Sanitizing Procedure - Final .................................................................................. 47

B. Maintenance ................................................................................................................ 49

C. Preparing the Icemaker for Long Storage ................................................................... 50

4

I. Specifications

AC SUPPLY VOLTAGE 115/60/1
AMPERAGE 9.0 A ( AT 104°F/ WT 80°F )
MINIMUM CIRCUIT AMPACITY N/A
MAXIMUM FUSE SIZE N/A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 * 303 (137) 290 (131) 278 (126)
Reference without *marks 80 267 (121) 256 (116) 246 (112)

90 236 (107) * 232 (105) 218 (99)

100 209 (95) 201 (91) * 188 (85)
SHAPE OF ICE Flake
ICE QUALITY Approx. 70%, Ice (90/70°F, Conductivity 200 µs/cm)
APPROXIMATE STORAGE CAPACITY 110 lbs.
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 674 (7.0) 667 (5.3)
POTABLE WATER 28 (12) 36 (12)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH) 36" x 24" x 33" (914 x 610 x 838 mm)
EXTERIOR FINISH PVC Coated Galvanized Steel; Galvanized Steel (Rear);

Stainless Steel (Top)
WEIGHT Net 182 lbs. ( 83 kg ), Shipping 221 lbs. ( 100 kg )
CONNECTIONS - ELECTRIC Cord Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Drain Pan 3/4" FPT

Bin Drain 3/4" FPT
ICE MAKING SYSTEM Auger type
HARVESTING SYSTEM Direct Driven Auger ( 1/6 HP Gear Motor )
ICE MAKING WATER CONTROL Float Switch
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. )
COMPRESSOR Hermetic, Model JS25C1E-IAA-252
CONDENSER Air-cooled, Fin and tube type
EVAPORATOR Copper Tube on Cylinder
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R-404A, 10.5 oz. (300 g)
DESIGN PRESSURE High 460 PSIG, Low 290 PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-off Relay
COMPRESSOR PROTECTION Auto-reset Overload Protector
GEAR MOTOR PROTECTION Manual reset Circuit Breaker
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch and Timer
ACCESSORIES - SUPPLIED Ice Scoop, Spare Fuse

- REQUIRED Legs
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V

AMBIENT TEMP. 45 - 100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG

A. Icemaker

1. F-300BAF

Note: We reserve the right to make changes in specifications and design without prior

notice.

5

II. General Information

A. Construction

1. F-300BAF

Bin Control *

Ice Storage Bin

Evaporator

Gear Motor

Compressor

Spout

Sliding Door

Control Water Valve

Reservoir

Expansion Valve

Control Box

Air-cooled Condenser

*The switch actuator is located in the ice storage bin.

6

B. Ice Making Unit

7

C. Control Box Layout

TRANSFORMER

CAPACITOR
GEAR MOTOR

START
CAPACITOR

FLUSH
RELAY

PRESSURE
SWITCH

CIRCUIT
PROTECT
RELAY

WATER
CONTROL
RELAY

GEAR MOTOR
PROTECT
RELAY

CONTROL
TIMER

FLUSH
SWITCH

POWER
SWITCH

CONTROL BOARD
FUSE (1A)

CIRCUIT
BREAKER
GEAR MOTOR

1. F-300BAF

a) Auxiliary Code K-1 and Earlier

b) Auxiliary Code K-2 and L-0

CONTROL TIMER

FLUSH SWITCH

POWER SWITCH

CONTROL BOARD
FUSE (1A)

GEAR MOTOR
FUSE (1.5A)

Note: The above component names are identical with the wiring label, but not with

TRANSFORMER

the parts list.

GEAR MOTOR
PROTECT RELAY

WATER CONTROL
RELAY

CAPACITOR - GEAR
MOTOR

CIRCUIT PROTECT
RELAY

PRESSURE SWITCH

FLUSH RELAY

START CAPACITOR

8

c) Auxiliary Code L-1 and M-0

CONTROL TIMER

FLUSH SWITCH

POWER SWITCH

CONTROL BOARD
FUSE (1A)

GEAR MOTOR
FUSE (1.5A)

GEAR MOTOR
PROTECT RELAY

TRANSFORMER

WATER CONTROL
RELAY

PRESSURE SWITCH

FLUSH RELAY

START CAPACITOR

CAPACITOR - GEAR
MOTOR

d) Auxiliary Code M-1 and Later

GEAR MOTOR

CONTROL TIMER

FLUSH SWITCH

POWER SWITCH

CONTROL BOARD
FUSE (1A)

GEAR MOTOR
FUSE (1.5A)

BIN CONTROL
SAFETY SWITCH
LAMP

TRANSFORMER

PROTECT RELAY

WATER CONTROL
RELAY

CAPACITOR - GEAR
MOTOR

SAFETY RELAY

PRESSURE SWITCH

FLUSH RELAY

START CAPACITOR

Note: The above component names are identical with the wiring label, but not with

the parts list.

9

D. Timer Board

1. Solid-State Timer Board Control

• A HOSHIZAKI exclusive solid-state sequence timer board is employed in Hoshizaki self­contained flaker icemakers.

• All models are pre-tested and factory-adjusted.

CAUTION

1. Fragile, handle very carefully.

2. The timer board contains CMOS (Complementary Metal-Oxide
Semiconductor) integrated circuits, which are susceptible to failure due to
static discharge. It is especially important to use an anti-static wrist strap
when handling or replacing the board.

3. Do not touch the electronic devices on the board or the back of the board to
prevent damage to the board.

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

5. Do not fix the electronic devices or parts on the board in the field. Always
replace the whole board assembly if it goes bad.

The timer board provides the following safeguards:

• Provides component protection during low water supply.

• Purges remaining ice in the evaporator.

• Provides short cycle protection for the compressor.

10

E. Sequence of Operation

Hoshizaki utilizes a solid state timer board to switch the components on and off as
needed. The sequence is as follows:

1. Startup

Flush switch in "ICE" position, power switch in "ON" position. FR energizes.

2. Fill Cycle

WV opens and the reservoir fills with water until UF/S closes. Note: GM will not start
unless UF/S is closed. For details, see "IV. Service Diagnosis".

3. Ice Purge Cycle (60 seconds)

WCR energizes, closing the low water safety circuit and de-energizing WV. GMR
energizes (clear relay located on TB). GM starts and GMPR energizes. GM runs for 60
seconds to clear any ice from the evaporator.
Note: Low water safety circuit is terminals 3 and 4 on TB.

4. Freeze Cycle (Ice Making Process)

CR energizes (black relay located on TB). Comp and FMS 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.
UF/S and LF/S operate WV as needed to continue the ice making process. This
continues until BC shuts the ice maker down or power is turned off to the unit.

5. Shutdown:

BC activates (opens). FR de-energizes, FWV energizes. Approximately 90 seconds after
BC activates, Comp and FMS de-energize, one minute later GMPR de-energizes and
GM stops.

Legend: BC–bin control; Comp–compressor; CR–compressor relay; FMS–self-
contained fan motor; FR–flush relay; FWV–flush water valve; GM–gear motor;
GMPR–gear motor protect relay; GMR–gear motor relay; LF/S–lower float
switch; TB–timer board; UF/S–upper float switch; WCR–water control relay;
WV–inlet water valve.

F. 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 unit 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.

11

If refill achieved, icemaking

cycle starts and timers

are reset.

4. Low Water Safety

Refill Cycle

UF/S closes terminating

90 sec TC.

60 sec. timer

90 sec. timer

If refill > 90 sec. TC

GM de-energized

GMPR de-energized

UF/S open

90 sec. TC exceeded

LF/S closed

UF/S closed

90 sec. TC ended

Comp de-energized

WCR de-energized

WV continues

FMS de-energized

WCR energized

FR continues

WV continues

WV continues

WV de-energized

Comp continues

GM continues

GM continues

Comp continues

GMPR continues

FMS continues

GM continues

FR continues

FMS continues

GMPR continues

FR continues

GMPR continues

FR continues

5. Compressor and fan

motor energize. Ice

production begins in 4

to 6 minutes.

60 seconds

4. Bin control proximity switch

closes. Reservoir fills. LF/S

and UF/S close. Gear motor

starts 6.7 seconds later.

6.7 sec.

Comp energized

FMS energized

LF/S and UF/S close

WCR energized

BC closed

FR energized

GM continues

WV de-energized

WV energized

GMPR continues

GM energized

FWV de-energized

WCR continues

GMPR energized

FR continues

FR continues

UF/S open

LF/S open

90 sec. TC started

WCR de-energized

WV energized

Comp continues

LF/S opens

initiating refill

60 sec. timer

and 90 sec. TC

Comp energized

FMS energized

WCR continues

GM continues

GMPR continues

3. Icemaking Cycle

2. Ice Purge Cycle

F-300BAF, F-500BAF Sequence Flow Chart and Component Operation

LF/S closed

UF/S closed

WCR energized

WV de-energized

GM continues

FR continues

GM energized

FMS continues

GMPR energized

GMPR continues

FR continues

FR continues

3. Gear motor de-energizes

and unit is "OFF"

GM de-energized

GMPR de-energized

FWV continues

60 seconds

2. Compressor and fan motor

de-energize, gear motor

continues running.

Comp de-energized

FMS de-energized

GM continues

90 seconds

BC open

FR de-energized

1. Bin control proximity switch

opens to stop ice production.

WCR de-energized

GMPR continues

FWV energized

FWV continues

Comp continues

FMS continues

GM continues

GMPR continues

Components Energized when the Flush Switch is in the FLUSH Position

The FLUSH position is used when cleaning and sanitizing the machine. When in the FLUSH position, power is

supplied to the flush valve. This allows cleaner and sanitizer to drain from the evaporator assembly.

1. Startup

1. Fill Cycle

Flush switch in "ICE"

Power switch "ON"

FR energized

WCR de-energized

WV energized

Low water safety ciruit

closed. (Terminals 3

and 4 on timer board)

Bin control operation

12

2. Shutdown & Restart

Legend:

BC - bin control

Comp - compressor

FMS - self-contained fan motor

FR - flush relay

FWV - flush water valve

GM - gear motor

GMPR - gear motor protect relay

LF/S - lower float switch

TC - timer control

UF/S - upper float switch

WCR - water control relay

WV - inlet water valve

III. Technical Information

A. Water Circuit and Refrigeration Circuit

F-300BAF

13

B. Wiring Diagram

1. Auxiliary Code K-1 and Earlier

14

F-300BAF

2. Auxiliary Code K-2 and L-0

15

F-300BAF