Hoshizaki TM-500AAE Service Manual

NO. E2TA-684
ISSUED: SEP. 23, 2005
REVISED: JUN. 26, 2007

HOSHIZAKI

THIN GLASS ICE MAKER

SERVICE MANUAL

MODEL TM-500AAE

i

CONTENTS PAGE

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

1. FEATURES ---------------------------------------------------------------------------------------- 1
[a] FLOOR MOUNTING AND FIXED MOUNTING ---------------------------------------- 1
[b] BIN CONTROL ADJUSTMENT (Fixed Mounting Only) ------------------------------ 1
[c] ICE PRODUCTION CONTROL (Fan Control)------------------------------------------ 1
[d] OVERLOAD PROTECTION --------------------------------------------------------------- 1
[e] USER RESET--------------------------------------------------------------------------------- 1
[f] ERROR CODES AND RECORDS------------------------------------------------------- 1
[g] OTHER INFORMATION--------------------------------------------------------------------- 2
[h] CHANGE OF ICE TYPE -------------------------------------------------------------------- 2

2. DIMENSIONS/CONNECTIONS --------------------------------------------------------------- 3

3. SPECIFICATIONS ------------------------------------------------------------------------------- 4

4. CONSTRUCTION--------------------------------------------------------------------------------- 5

II. MAINTENANCE AND CLEANING INSTRUCTIONS ------------------------------------------ 6

1. TIMING BELT -------------------------------------------------------------------------------------- 6

2. CONDENSER------------------------------------------------------------------------------------- 6

3. AIR FILTER ---------------------------------------------------------------------------------------- 6

4. GREASE UP (BEARING)----------------------------------------------------------------------- 6

5. PERIODICAL CLEANING ---------------------------------------------------------------------- 7

III. TECHNICAL INFORMATION----------------------------------------------------------------------- 8

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT ---------------------------------------- 8

2. WIRING DIAGRAM ------------------------------------------------------------------------------- 9
[a] WIRING DIAGRAM--------------------------------------------------------------------------- 9
[b] CONTROL BOX LAYOUT -----------------------------------------------------------------10

3. ICEMAKING MECHANISM--------------------------------------------------------------------11
[a] EVAPORATOR (DRUM) ------------------------------------------------------------------11
[b] CUTTER---------------------------------------------------------------------------------------11
[c] BEARING--------------------------------------------------------------------------------------11
[d] MECHANICAL SEAL ----------------------------------------------------------------------11
[e] HEATER (CUTTER) ------------------------------------------------------------------------12
[f] HEATER (TANK) ----------------------------------------------------------------------------12
[g] GEAR MOTOR-------------------------------------------------------------------------------12

4. WATER CIRCUIT --------------------------------------------------------------------------------12
[a] FLOAT SWITCH-----------------------------------------------------------------------------12
[b] CONTROL WATER VALVE --------------------------------------------------------------12
[c] FLUSH WATER VALVE-------------------------------------------------------------------13
[d] DRAINING ICEMAKER IN SUBFREEZING CONDITIONS-------------------------13

5. REFRIGERATION CIRCUIT -------------------------------------------------------------------14
[a] APPLICABLE PARTS ---------------------------------------------------------------------14
[b] SERVICE INSTRUCTIONS ---------------------------------------------------------------14
[c] REFRIGERANT CONTROL (Compressor Cooling) ---------------------------------14
[d] REFRIGERANT CONTROL (Ice Production Control) -------------------------------14
[e] REFRIGERANT------------------------------------------------------------------------------14

ii

[f] COMPRESSOR -----------------------------------------------------------------------------15
[g] EVAPORATOR (DRUM) ------------------------------------------------------------------15
[h] CONDENSER--------------------------------------------------------------------------------15
[i] CONDENSER COOLING FAN MOTOR -----------------------------------------------16
[j] DRIER ------------------------------------------------------------------------------------------16
[k] SOLENOID VALVE-------------------------------------------------------------------------16
[l] THERMOSTATIC EXPANSION VALVE -----------------------------------------------16
[m] ACCESS VALVE --------------------------------------------------------------------------16
[n] RECEIVER TANK ---------------------------------------------------------------------------16

6. ELECTRIC CIRCUIT ----------------------------------------------------------------------------17
[a] BASIC OPERATION------------------------------------------------------------------------17
[b] TIMING CHART (Floor Mounting) --------------------------------------------------------18
[c] TIMING CHART (Fixed Mounting)--------------------------------------------------------19
[d] SEQUENCE----------------------------------------------------------------------------------20
[e] OPERATION BOARD ----------------------------------------------------------------------33
[f] CONTROLLER BOARD -------------------------------------------------------------------33
[g] CAPACITOR - XY FILTER ----------------------------------------------------------------33
[h] BIN CONTROL SWITCH (Fixed Mounting Only) --------------------------------------34
[i] SPOUT SWITCH (Proximity Switch) ----------------------------------------------------34
[j] CRANKCASE HEATER -------------------------------------------------------------------34

7. OPERATION BOARD --------------------------------------------------------------------------35
[a] US ER OP ERATI ON ------------------------------------------------------------------------35
[b] SERVICE OPERATION--------------------------------------------------------------------36

8. PROTECTORS ----------------------------------------------------------------------------------37
[a] INDICATION ----------------------------------------------------------------------------------37
[b] PROTECTORS ------------------------------------------------------------------------------37

9. ERROR CODES---------------------------------------------------------------------------------39

10. PERFORMANCE DATA ----------------------------------------------------------------------41
[a] TM-500AAE (Thick Ice) --------------------------------------------------------------------41
[b] TM-500AAE (Thin Ice)----------------------------------------------------------------------42

IV. SERVICE DIAGNOSIS ----------------------------------------------------------------------------43

1. NO ICE PRODUCTION-------------------------------------------------------------------------43

2. LOW ICE PRODUCTION ----------------------------------------------------------------------44

3. OTHERS-------------------------------------------------------------------------------------------45

V. REMOVAL AND REPLACEMENT OF COMPONENTS -----------------------------------46

1. SERVICE FOR REFRIGERANT LINES ----------------------------------------------------46
[a] SERVICE INFORMATION-----------------------------------------------------------------46
[b] REFRIGERANT RECOVERY ------------------------------------------------------------47
[c] EVACUATION AND RECHARGE-------------------------------------------------------47

2. BRAZING ------------------------------------------------------------------------------------------48

3. COMPRESSOR ---------------------------------------------------------------------------------49

4. DRIER----------------------------------------------------------------------------------------------50

5. EXPANSION VALVE---------------------------------------------------------------------------51

6. EVAPORATOR ASSEMBLY -----------------------------------------------------------------52

7. CONTROL WATER VALVE ------------------------------------------------------------------58

iii

8. FLUSH WATER VALVE -----------------------------------------------------------------------59

9. CONTROLLER BOARD -----------------------------------------------------------------------60

10. LINE VALVE--------------------------------------------------------------------------------------60

1

I. SPECIFICATIONS

1. FEATURES

[a] FLOOR MOUNTING OR FIXED MOUNTING

The floor mounting and fixed mounting options are available. Use the rotary Select Switch
provided on top of the Operation Panel to choose between the two options. If the fixed mounting
option is selected, the Bin Control Switch in the Control Box will become functional.

[b] BIN CONTROL ADJUSTMENT (Fixed Mounting Only)

The sensitivity of the Bin Control Switch in the Control Box is factory-adjusted for the standard
Storage Bin B-500. If requested by the customer, it is adjustable by turning the Adjust Screw on
the Bin Control Switch. See "4. BIN CONTROL ADJUSTMENT" in the installation manual for
further details.

[c] ICE PRODUCTION CONTROL (Fan Control)

The ice production will increase at low ambient or water temperature. As a result, the Gear
Motor will have a higher torque to harvest ice, and the icemaking mechanism will be overloaded.
To prevent this condition, the icemaker controls the Fan Motor rotation speed to keep the
discharge pressure in the refrigeration circuit within a proper range.

[d] OVERLOAD PROTECTION

Despite the above-mentioned ice production control, some use conditions (water quality etc.)
or variable part tolerances may overload the icemaking mechanism. A photomicrosensor will
detect overload by reduction in Drum rotation speed and shut down the icemaker. This can
avoid a costly breakdown of the icemaking mechanism or the like.

[e] USER RESET

When a protector trips to shut down the icemaker, an error code will be displayed. If it is a
resettable error, the user can restart the icemaker by pressing the Reset Button accessible from
the Window Panel and continue the icemaking operation until a service person arrives. Some
errors are non-resettable or repetitive and require troubleshooting by qualified personnel.

[f] ERROR CODES AND RECORDS

When the icemaker shuts down with an error, the Display Window will show an error code "E_".
A maximum of eight most recent records are memorized and can be checked at the time of
service or inspection.

2

[g] OTHER INFORMATION

Other information is also available from the Controller Board. See "III. 7. OPERATION BOARD"
for details.

[h] CHANGE OF ICE TYPE

The ice type is changeable by replacing the Pulleys provided on the Gear Motor and Gear Head
driving the Evaporator (Drum). The icemaker is factory-adjusted in the "Thick Ice" mode, but
can be changed to the "Thin Ice" mode by replacing the Pulleys.

3

2. DIMENSIONS/CONNECTIONS

4

3. SPECIFICATIONS

AC SUPPLY VOLTAGE
AMPERAGE
STARTING AMPERAGE
ELECTRIC CONSUMPTION
POWER FACTOR
POWER SUPPLY CAPACITY

1 PHASE 230V 50Hz

10.3A (Ambient temp. 32°C, Water temp. 21°C)

75.9A
2035W (Ambient temp. 32°C, Water temp. 21°C)

85.6%
Min 4.8kVA (20.9A)

ICE PRODUCTION PER 24h Thick Ice Thin Ice

Approx. 520 kg 630 kg (Ambient temp. 10°C, Water temp. 10°C)
Approx. 460 kg 550 kg (Ambient temp. 21°C, Water temp. 15°C)
Approx. 380 kg 460 kg (Ambient temp. 32°C, Water temp. 21°C)

WATER CONSUMPTION PER 24h Thick Ice Thin Ice

Approx. 0.53 m

3

0.64 m3 (Ambient temp. 10°C, Water temp. 10°C)

Approx. 0.47 m

3

0.56 m3 (Ambient temp. 21°C, Water temp. 15°C)

Approx. 0.39 m

3

0.47 m3 (Ambient temp. 32°C, Water temp. 21°C)
SHAPE OF ICE
MAX. STORAGE CAPACITY

Scale Ice

Not Applicable
DIMENSIONS (DRAWING No.)
EXTERIOR
CONNECTION - ELECTRIC

- WATER SUPPLY

- DRAIN

761(W) x 524(D) x 800(H) (362948)

Stainless Steel, Galvanized Steel (Rear)

Y-type Con.

Inlet G 3/4” (Connected at rear side)

Outlet R 3/4” (Connected at rear side)
ICE MAKING SYSTEM
HARVESTING SYSTEM

Drum type

Continuous ice making system
COMPRESSOR
CONDENSER

HEAT REJECTION
EVAPORATOR
REFRIGERANT CONTROL
REFRIGERANT CHARGE

Hermetic Compressor Model CS20K6E-PFZ
Fin and Tube type, Air-cooled (Fan Motor output 30W)
2980W (Ambient temp. 32°C, Water temp. 21°C)
Aluminum Horizontal Drum
Thermostatic Expansion Valve

R404A 1900g
BIN CONTROL SYSTEM
ICE MAKING WATER CONTROL

Infrared ray Sensor (Time Delay Controlled)

Float Switch and Water Valve
ELECTRICAL PROTECTION
REFRIGERATION CIRCUIT
PROTECTION
GEAR MOTOR PROTECTION
LOW WATER PROTECTION
BIN CONTROL PROTECTION
INTERLOCK

Class I Appliance, 3.15A Fuse

Compressor Internal Motor Protector, Internal Pressure Relief Valve,

Pressure Switch (Auto-reset)

Thermal Protector (Auto-reset), Motor Rotation Protection

Float Switch and Microprocessor

Micro Switch (Manual-reset)

Shutdown by Microprocessor (Manual-reset)
WEIGHT
PACKAGE

Net weight 152 kg / Gross weight 166 kg

Carton 865mm(W) x 700mm(D) x 972mm(H)
ACCESSORIES Installation Kit
OPTION Chute, Top Kit
OPERATION CONDITIONS
AMBIENT TEMP.
WATER SUPPLY TEMP.
WATER SUPPLY PRESSURE
VOLTAGE RANGE

5-40°C

5-35°C

0.5-8 bar (0.05-0.8MPa)

Rated Voltage ± 10%
We reserve the right to make changes in specifications and design without prior notice.

5

4. CONSTRUCTION

Control Water Valve

Float Switch

Expansion Valve

Gear Motor

Receiver Tank

Drier

Fan Motor

Line Valve

Control Box - Main

Control Box - Operation

Pressure Switch

Icemaking Unit

Flush Water Valve

Compressor

To

p

View

Front View

Left Side View Right Side View

6

II. MAINTENANCE AND CLEANING INSTRUCTIONS

IMPORTANT

This icemaker must be maintained individually , referring to the instruction manual
and labels provided with the icemaker.

1. TIMING BELT

The Timing Belt transmits power from the Gear Motor to the Gear Head. It may wear or deteriorate
and break after a total of 15,000 hours of Gear Motor operation.

2. CONDENSER

Check the Condenser once a year, and clean if required by using a brush or vacuum cleaner.
More frequent cleaning may be required depending on the location of the icemaker.

3. AIR FILTER

A plastic mesh Air Filter removes dirt or dust from the air , and keep s the Condenser from getting
clogged. As the Filter get s clogged, the icemaker’s performance will be reduced. Remove and
clean the Air Filter at least twice per month:

1) Push down the Lock and take off the Louver .
Note: Do not put your hand inside the machine compartment.

2) Remove the Air Filter by pushing it down.

3) Clean the Air Filter by using a vacuum cleaner. When severely
clogged, use warm water and a neutral cleaner to wash the Air
Filter.

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

4. GREASE UP (BEARING)

The Bearing supporting the Drum rotation requires periodic greasing. Use Dow Corning G­4500 to grease up the Bearing once a year. See step 32) in "V. 7. EV APORATOR ASSEMBL Y"
for the replacement procedure.

Exterior Panel

Lock

Air Filter

Louver

7

5. PERIODICAL CLEANING

1) Machine and Bin Exterior

Wipe the exterior at least once per week with a clean, soft cloth. Use a damp cloth containing a
neutral cleaner to wipe off grease or dirt.

2) Storage Bin Interior Cleaning/Sanitisation (as required) [fixed mounting only]

1) Open the Storage Bin Door, and remove all ice.

2) Wash the Bin Liner , Ice Deflector and Door inner surface with a neutral non-abrasive cleaner .
Rinse thoroughly with a clean cloth and fresh water.

3) Mix 5 litres of water with 18 mL of 5.25% sodium hypochlorite solution in a suitable container
or the recommended Hoshizaki sanitiser as directed.

4) Soak a clean sponge or cloth with the solution and wipe all the surfaces of the Bin Liner, Ice
Deflector and Door inner surface.

5) Rinse thoroughly with fresh water and a clean cloth to wipe off the solution. Close the Bin
Door.

Note: Some solutions may cause damage to the Bin liner surfaces or corrosion on the metal

parts. Always rinse the sanitiser unless directed otherwise by Hoshizaki guidelines.

8

III. TECHNICAL INFORMATION

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

Pressure Switch

Low Side

Cut-out 0.03 ± 0.02 MPa
Cut-in 0.1 ± 0.02 MPa

High Side

Cut-out 3.2 ± 0.02 MPa
Cut-in 2.55 ± 0.02 MPa

9

2. WIRING DIAGRAM

[a] WIRING DIAGRAM

10

[b] CONTROL BOX LAYOUT

11

3. ICEMAKING MECHANISM

[a] EVAPORATOR (DRUM)

The Evaporator consists of an aluminum alloy cylinder with an icemaking surface on its exterior,
a press-fit plastic part with a refrigerant path, and a shaft for refrigerant supply and rotation. The
Evaporator penetrates the side of the Tank, and the Cutter scrapes off ice forming on the
Evaporator surface.

[b] CUTTER

The stainless steel Cutter is fixed on the Tank so that it can be repositioned against the Evaporator.

[c] BEARING

The Bearing is installed on one side of the Tank to support the Evaporator (Drum) Shaft. The
Gear Head provides the same function on the other side of the Tank where the Gear Motor is
located to drive the Drum.

[d] MECHANICAL SEAL

The Mechanical Seal prevents refrigerant leaks from the rotating Drum. The rotary ring attached
to the Shaft and the stationary ring fixed on the Housing form a carbon ring shaft sealing system.

12

[e] HEATER (CUTTER)

The Heater provided on the backside of the Cutter prevents ice jamming on the Cutter resulting
in a clogged Spout and ice forming on the back of the Cutter at a low temperature. The thermal
sensor attached on the water inlet controls to energize the Heater.

[f] HEATER (TANK)

The Heater provided inside the Tank prevents the Float Switch from freezing. As with the Heater
for the Cutter, the thermal sensor attached on the water inlet controls to energize the Heater.

[g] GEAR MOTOR

The Gear Motor consists of a 1 phase 230V drive motor integrated with a decelerator and
provided with a built-in auto-reset Thermal Protector. When the Thermal Protector trips, the
Controller Board will stop the Gear Motor. The Protector can be reset by the Reset Button on
the Operation Board. The Thermal Protector trips when the Gear Motor mechanism is overloaded
or when excessively high or low voltage is applied on the Gear Motor. The electrical capacity
must be increased if a large current flows through the surrounding equipment.

4. WATER CIRCUIT

[a] FLOAT SWITCH

The Tank holding the Evaporator is provided with a plastic Float Switch to detect the water level.
The floats move up and down along with the water level and send ON/OFF signals to open/close
the Water Valve in order to maintain the proper water level.
If the proper water level cannot be resumed within about 20 minutes after the Float Switch sends
an OFF signal, the icemaker will detect a low water condition and shut down. The icemaker will
automatically restart icemaking operation when the proper water level is resumed within 80
minutes.
If the Float Switch trips at the upper float level for 10 minutes after the Tank fills up, the icemaker
will display “E1” for no ice production error and shut down.
If the Float Switch trips at both upper (fill) and lower (empty) float levels, the icemaker will display
“E2” for a switch contact error and shut down.
See “9. ERROR CODES” for details.

[b] CONTROL WATER VALVE

The Control Water Valve located above the Tank will open to supply water to the Tank when the
coil is energized. Despite the water pressure varying from 0.3 bar to 8 bar at the water supply
inlet, the built-in flow controller maintains almost the same water flow (100V AC).

13

[c] FLUSH WATER VALVE

The Flush Water Valve is energized to open and flush out the Tank (100V AC) after the icemaker
shuts down and every 12 hours when the Storage Bin is used.

[d] DRAINING ICEMAKER IN SUBFREEZING CONDITIONS

In winter, the water circuit must be completely drained out or otherwise protected to prevent
freeze-up and damage before shutting down the icemaker at night.

1) Close the Water Supply Line Shut-off Valve to stop water supply.

2) Open the Air Shut-off Valve.

3) Press the Stop Button, and drain the Float Tank and Evaporator.

4) Turn off the icemaker.
Before restarting the icemaker:

1. Close the Air Shut-off Valve.

2. Open the Water Supply Line Shut-off Valve.

14

5. REFRIGERATION CIRCUIT

[a] APPLICABLE PARTS

Refrigerant (R404A)
Compressor
Evaporator Tank
Air-cooled Condenser
Air-cooled Condenser Fan Motor (1 pc)
Drier
Solenoid Valve
Strainer
Thermal Expansion Valve
Access Valve
Heat Exchanger

[b] SERVICE INSTRUCTIONS

Always restore the original bindings after servicing the refrigeration circuit. Otherwise, vibration
may cause overstress and damage to the circuit, resulting in refrigerant leak.

After replacing the Evaporator (Drum), Mechanical Seal, Bearing, or Oil Seal, run the icemaker
for 30 minutes to produce ice, check for impurities, and discard.

[c] REFRIGERANT CONTROL (Compressor Cooling)

See “1. WATER AND REFRIGERANT CIRCUIT”.

Fan Cooling

The Fan Motor blows air over the Compressor to release its heat.

[d] REFRIGERANT CONTROL (Ice Production Control)

Fan Speed Control

Increased ice production in a low temperature condition will overload and damage the icemaking
mechanism. To control the ice production, the Controller Board energizes and de-energizes
the Fan Motor to reduce its rotation speed.

[e] REFRIGERANT

The icemaker employs refrigerant R404A which itself is not flammable or poisonous. However,
a small room filled with R404A may cause suffocation with a lack of oxygen. Also, when exposed

15

to an open flame, R404A creates Phosgene gas, hazardous in large amounts. Handle the
refrigerant in a well-ventilated area with no flames.

Always recover the refrigerant and store it in a proper container, if required by an applicable
law. Do not discharge the refrigerant into the atmosphere.

[f] COMPRESSOR

The Compressor absorbs the low-pressure refrigerant gas vaporized in the Evaporator (to reduce
the pressure inside the Evaporator), compresses the refrigerant into high-temperature high­pressure gas, and sends it out to the Condenser.
The hermetic-type Compressor is efficient in refrigeration, and the refrigeration circuit is designed
to endure long hours of operation. The Compressor is mounted on vibration damping rubber to
prevent transmission of vibration. In case of accidental overload, the Case Thermostat or
Overload Relay will shut down the Compressor. The Reset Button must be pressed to reset the
Overload Relay.

[g] EVAPORATOR (DRUM)

The Evaporator is a drum with shafts at both ends and a refrigerant path between a metallic
exterior and a plastic interior. The refrigerant flows through a very narrow path in the Expansion
Valve with a sudden drop of pressure and evaporates by absorbing heat of vaporization from
the Evaporator. The water supplied inside the Tank holding the Evaporator is deprived of heat
and forms thin ice around the Evaporator, which will be scraped off by the Cutter.

[h] CONDENSER

The Condenser refrigerates and liquefies the high-temperature high-pressure refrigerant gas
discharged from the Compressor into high-pressure liquid refrigerant.
A dirty Condenser will significantly reduce the refrigeration efficiency and performance, and will
also shorten the service life of the components (especially refrigeration circuit). The Condenser
must be cleaned according to the following instructions. The frequency of cleaning depends on
the installation conditions.

Air-cooled Condenser (Fin-and-tube type)

A copper tube is attached on a finned aluminum plate with high heat conductivity to promote
heat radiation, and a Fan Motor is also provided for forced air cooling. A remote type Condenser
is also available to protect the interior from noise of the Fan Motor and temperature rise by heat
radiation.
Use a vacuum cleaner or brush to remove dirt and dust between the fins. Be careful not to bend
the fins.

16

[i] CONDENSER COOLING FAN MOTOR

The Fan Motor cools the Air-cooled Condenser and sends air to condense refrigerant gas inside
the Condenser.

[j] DRIER

The Drier uses desiccants (molecular sieves + activated alumina) to absorb moisture in the
refrigeration circuit. The built-in filter also corrects foreign matter in the refrigeration circuit to
prevent troubles with valves clogged with dirt or moisture.

[k] SOLENOID VALVE

The Solenoid Valve is provided for pump down control to prevent refrigerant gas from remaining
inside the Evaporator and causing liquid return at restart.

[l] THERMOSTATIC EXPANSION VALVE

The Expansion Valve throttles high-pressure liquid refrigerant into low-temperature low-pressure
state by adiabatic expansion and maintains the proper amount of refrigerant supply depending
on the Evaporator load. The Thermostatic Expansion Valve controls the valve position to regulate
the superheat (difference between evaporating temperature and suction gas temperature). No
superheat control is available from outside.
To check the Expansion Valve for proper operation, remove the Bulb while the Compressor is
running. If the suction pressure rises, the Expansion Valve is working normally.

Note: Do not leave the Bulb removed for a long time while the Compressor is running. The
Compressor may fail due to liquid return.

[m] ACCESS VALVE

The Access Valve connects the inside and outside of the refrigeration circuit to allow evacuation,
recharge, and pressure measurement.

Note: When replacing (brazing) the Access Valve, remove the valve core to prevent the
rubber part from melting. The valve is sealed by the core only. Always cap the valve while
not in use. Tighten the seal nut to the torque of 9.81 - 12.26Nm to prevent gas leaks.

[n] RECEIVER TANK

The Receiver Tank temporarily stores excess liquid refrigerant which may be caused by a change
in ambient temperature. The Access Valve provided for servicing can also be used to check
the high-side pressure.

17

6. ELECTRIC CIRCUIT

CAUTION

Reassemble all the components as they were after servicing the unit according to
a service call.

[a] BASIC OPERATION

The icemaker starts water supply when the Operation Switch is turned ON and the Ice Button is
pressed (floor mounting) or in 30 seconds after the Bin Control Switch checks that the Storage
Bin is not filled with ice (fixed mounting). On completion of water supply, the Fan Motor starts
and the Line Valve opens. After 120 seconds the Compressor starts, and then after 15 seconds
the Gear Motor starts to begin icemaking operation.

When the Stop Button is pressed or the Bin Control Switch trips (fixed mounting only), the icemaker
stops icemaking operation, starts pumping down to drain water from the Tank, and finally shuts
down.
For fixed mounting only, the icemaker automatically starts the pump down cycle to drain water
every 12 hours after the Compressor starts. The icemaker starts water supply and resumes
icemaking operation in 8 minutes after the drain cycle completes.

The icemaker is equipped with fan speed control. It monitors the condenser center temperature
and slows down the fan rotation to regulate the condensing pressure. This function is to prevent
a mechanical trouble with overproduction of ice.

The Heater (Tank) and Heater (Cutter) are energized or de-energized depending on the water
supply temperature and continuously energized when the Thermistor reads a temperature below
5°C.

18

[b] TIMING CHART (Floor Mounting)

Stopbutton

SelectSW

OperationSW

Icebutton

Icemode

Stopmode

Waterlevel

UpperfloatSW

Drainmode

LowerfloatSW

ControlWV

FlushWV

LV

FM

CM

GM

PS(HIGH)

Bincontrol

15s 15s

480s

5

s

1

2

0

s

FloorMounting
FixedMounting

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

Upper

Lower

Bottom

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

5s

PS(LOW)

ON

OFF

120s

Nocontrol

19

[c] TIMING CHART (Fixed Mounting)

Stopbutton

SelectSW

OperationSW

Icebutton

Icemode

Stopmode

Waterlevel

UpperfloatSW

Drainmode

LowerfloatSW

ControlWV

FlushWV

LV

FM

CM

GM

PS(HIGH)

Bincontrol

15s 15s

480s

5s

1

2

0

s

FloorMounting
FixedMounting

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

Upper
Lower

Bottom

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

5s

PS(LOW)

ON

OFF

480s

120s

30s

20

[d] SEQUENCE
(1) Startup - Water Supply [Floor Mounting]

21

(1) Startup - Water Supply [Fixed Mounting]

22

(2) Startup - After completion of water supply, Fan Motor and Line Valve start in 2 min

[Floor Mounting]

23

(2) Startup - After completion of water supply, Fan Motor and Line Valve start in 2 min

[Fixed Mounting]

24

(3) Startup - After Fan Motor and Line Valve start, Compressor starts in 15 sec
[Floor Mounting]

25

(3) Startup - After Fan Motor and Line Valve start, Compressor starts in 15 sec
[Fixed Mounting]

26

(4) Startup - Ice production starts [Floor Mounting]

27

(4) Startup - Ice production starts [Fixed Mounting]

28

(5) Normal Operation - Bin control and drain cycle (480 sec) start [Fixed Mounting]

29

(6) Shutdown - After pump down and drain cycle (480 sec) start, Compressor stop s in
5 sec [Floor Mounting]

30

(6) Shutdown - After pump down and drain cycle (480 sec) start, Compressor stop s in
5 sec [Fixed Mounting]

31

(7) Shutdown - Drain [Floor Mounting]

32

(7) Shutdown - Drain [Fixed Mounting]

33

[e] OPERATION BOARD

The Operation Board is provided for operation of the icemaker. See “7. OPERATION
BOARD” for details.

[f] CONTROLLER BOARD

The icemaker is controlled by the Controller Board based on the following logic:

1) Ice Production Control

In a low ambient or water temperature condition, the ice production capacity will increase.
Then, the Gear Motor will have a larger torque to scrape off ice, which will overload the
entire icemaking mechanism. To prevent overload, the icemaker controls the fan rotation
speed.

2) Overload Protection

Despite the above control, the icemaker may be overloaded depending on the field
conditions (ex. water quality) or dimensional variation of the components. If the icemaker
is overloaded and the photomicrosensor detects a lower drum rotation speed than normal,
the icemaker will shut down before leading to critical and costly problems, such as with the
icemaking mechanism.

3) Error Code Indication

When the icemaker shuts down with a trouble, an error code will be displayed immediately
to notify the user. To facilitate servicing, ask the user for the applicable error code, and
prepare for the trouble in advance.

4) Flush Timer (Fixed Mounting Only)

The controller board is provided with a timer to count the total operation time up to 12
hours when the icemaker starts flushing. During the flush cycle, the display window will
illuminate “DRAIN”.
As the thin glass icemaker continuously produces ice, the content of substances included
in the icemaking water inside the icemaking unit is three to five times as high as that in
the supplied water. As a result, substances such as calcium, magnesium, and silica
contained in the water will attach and deposit inside the icemaking unit to reduce the ice
production capacity or accelerate wear on the moving parts.

[g] CAPACITOR - XY FILTER

The Capacitor - XY Filter is provided to prevent the Controller Board from signal errors

34

caused by internal and external noises.

[h] BIN CONTROL SWITCH (Fixed Mounting Only)

The Bin Control Switch is located in the Control Box - Main (see “2. [b] CONTROL BOX
LAYOUT”). The Bin Control Switch employs a photoelectric sensor to measure the depth
by reflected orange LED light. When the Bin Control Switch switches off at the set
distance, the Compressor pumps down and stops after 60 seconds, the Gear Motor stops
after 5 seconds, and the icemaker shuts down.
When stored ice is used, the sensor detects its reduction. Then, the Compressor restarts
after 30 seconds, and the Gear Motor after 15 seconds.

Note: The unit mounting surface requires a bin control hole as well as an ice discharge

hole. See “I. 2. DIMENSIONS/CONNECTIONS” for hole locations.

[i] SPOUT SWITCH (Proximity Switch)

When the Bin Control Switch fails to operate, ice clogs and deforms the Switch Plate to trip
the Spout Switch, and the icemaker shuts down with bin control error. When the error
occurs once (floor mounting) or repeats four times (fixed mounting), “EL” appears in the
display (see “9. ERROR CODES” for details). Remove ice in the Tank Cover (C) and on
the Cutter, and correct the Switch Plate before resuming icemaking operation.

Normal Condition Abnormal Condition (Switch Plate deformed)

[j] CRANKCASE HEATER

Equipments employing a large amount of refrigerant are provided with the Crankcase
Heater to prevent refrigerant migration to the Compressor during off-cycles resulting in oil
shortage at startup. The Crankcase Heater will be energized also when the user turns off
the Operation Switch on the Operation Board.

35

7. OPERATION BOARD

[a] USER OPERATION (accessible from the Window Panel)

Symbol Button Functions

Ice

Floor Mounting

: When pressed during shutdown, the unit will be
supplied with water and start icemaking operation. When
pressed in STOP mode, the unit will start icemaking operation.
Fixed Mounting

: When pressed during shutdown, the unit will be
supplied with water. If the storage bin is not full, the unit will
start icemaking operation.

Stop

When pressed in ICE mode, the unit will stop icemaking
operation. After stopping icemaking operation, the unit will
immediately drain and shut down.

Reset

When pressed after the unit stops with an error code displayed,
the unit may resume icemaking operation. Unless the cause of
the error has been corrected, the unit may stop again with the
same error code.

Operation

Starts and stops the icemaker’s operation. To shut down the
unit for a long time, turn this switch OFF in the STOP mode.
The Crankcase Heater will remain energized even with this
switch OFF.

Visible from
Window Panel

36

[b] SERVICE OPERATION (Remove the Front Panel for access to the service buttons)

CAUTION

Removal of the Front Panel will expose moving and hot parts. It is allowed for qualified
service personnel only.

Symbol Button Symbol Button

Option

Floor Mounting

Drum Rotation

Fixed Mounting

1) Drum Rotation Button

When pressed in the STOP mode (including error shutdown), the Drum will rotate
regardless of icemaking process.

2) Displaying Error Record

Keep pressing the Option Button in the ICE or STOP mode.
Press the Stop Button to display the error record.
A maximum of eight most recent errors will be displayed in reverse order of occurrence,
including those not informed to the user (not displayed).
“– –“ shows the end of the error record.
Release the Option Button to return to the original mode.

3) Resetting Error Record

With the Operation Switch in the OFF position, keep pressing the Stop + Option Buttons
together, and turn ON the Operation Switch.
Release the Buttons when the Display Window shows “00”.
The error record has been reset. Do NOT use this command unless necessary.

4) Mounting Mode Options

The mounting mode is usually selected between “floor mounting” and “fixed mounting” at
the time of installation by pressing the Select Switch. If a change is required after
installation, press the Select Switch with the Operation Switch in the OFF position.

37

When an error occurs, “E_” or ”c_”
will appear in the Display Window.

8. PROTECTORS

[a] INDICATION

When an operational error occurs, “E_” or “C_” will appear and blink in the Display Window
on the Operation Board, and the icemaker will stop. When a service call is received, ask
the user to check which error code is in the Display Window. Then, see the error code
table in “9. ERROR CODES” to locate the cause.

[b] PROTECTORS

1) Compressor

Internal Inherent Motor Protector
Senses a temperature rise of the Compressor, and internally shuts off the circuit.
Automatically resets when the temperature goes down. If the Compressor takes a long
time to restart, the Ice Production Timer may shut down the unit with “E1” in the Display
Window. In this case, press the Reset Button.

Internal Pressure Relief Valve
Allows discharge gas into the low side to prevent damage to the Compressor when the
discharge pressure rises excessively. The bypassed gas will trip the above-mentioned
Internal Inherent Motor Protector which will not reset until the temperature goes down.

38

2) Gear Motor

Thermal Protector
Provided on the motor coil. Operates when the motor temperature rises. The protector is
auto-reset, but the controller shuts down the icemaker. Press the Reset Button to restart.

Photomicrosensor
Counts the number of drum rotation and in case of abnormality, shuts down the icemaker
including the Gear Motor.

The above protectors indicate “EE” in the Display Window.

3) Fan Motor

The auto-reset Fuse attached to the motor coil will operate when the motor temperature
rises. For the air-cooled models, the High Pressure Switch will turn on and off the
icemaker. “E4” may appear in the Display Window.

4) Heater

When the Heater overheats, the Thermal Fuse connected in parallel will operate at 75°C.
Auto-reset.

5) Overcurrent Protector

Trips to shut down the icemaker in case of overcurrent conditions. Manual-reset.

6) Spout Switch

If the Bin Control Switch fails to operate, the Spout will be clogged with ice. A proximity
switch is installed to prevent this trouble. When the Spout Switch trips, the icemaker will
shut down. If the Spout Switch resets but trips again within 5 minutes, and if this error
occurs four times in total (fixed mounting only), “EL” will blink in the Display Window.

7) Low Water

In case of low water or clogged water supply circuit, the icemaker will shut down unless the
Float Switch trips at the upper float level within 20 minutes with the Water Valve left open.
If the error occurs once (floor mounting) or repeats three times in total (fixed mounting),
“C1” will appear in the Display Window.

8) Ice Production Timer

Detects ice production error if the Float Switch keeps tripping at the upper float level for 10

39

minutes while the Compressor is running, and stops icemaking operation. “E1” will appear
in the Display Window.

9) Thermistor

The code “EA” (Water Temperature Thermistor) or “Eb” (Condenser Center Thermistor) will
blink in the Display Window if the Thermistor circuit detects infinite resistance (open circuit
or bad contact).

10) Float Switch

The Float Switch or connector may have a bad contact if the Float Switch trips at the upper
float level but not at the lower float level with the Flush Water Valve closed. “E2” will
appear in the Display Window.

11) High Pressure Switch

Operates at a high condensing pressure when the icemaker has a clogged Air Filter or a
dirty Condenser. “E4” will appear in the Display Window when the Pressure Switch trips
once (floor mounting) or five times within an hour (fixed mounting).

9. ERROR CODES

Interlock Errors

Code Error Condition Operation Reset Check/Repair

E1

Abnormal Ice
Production

During Compressor
operation, Float Switch trips
at upper float level for 10
minutes.

Whole unit
stops.

Press
Reset
Button.

Float Switch,
Control Water Valve
not closing,
Refrigeration circuit,
Gas leak, Freeze

E2

Float Switch
Error

Float Switch trips at both
upper and lower float levels
for 2 seconds.

Whole unit
stops.

Press
Reset
Button.

Float Switch

E4

Abnormal
High Side
Pressure

High Pressure Switch trips
once (floor mounting) or 5
times in 1 hour of
Compressor operation
(fixed mounting).

Whole unit
stops.

Press
Reset
Button.

Fan Motor,
Refrigeration circuit,
Condenser
clogged, Installation
conditions

E9

Abnormal Low
Side Pressure

During Compressor
operation, Low Pressure
Switch trips for 5 seconds.
“E9” appears immediately
(floor mounting) or after 2
repetitions (fixed mounting).

Whole unit
stops.

Press
Reset
Button.

Miswiring, Gear
Motor Magnet
Switch or Relay
Replace Controller
Board.

EA

Water Inlet
Thermistor
Circuit Open

Water temperature stays
below -50°C for 1 second.

Fan control
stays at full
speed. Heater
control is OFF.

Press
Reset
Button.

Water Inlet
Thermistor

40

Code Error Condition Operation Reset Check/Repair

Eb

Condenser
Center
Thermistor
Circuit Open

Condenser temperature
stays below -50°C for 1
second.

Fan control
stays at full
speed.

Press
Reset
Button.

Condenser Center
Thermistor

EC

Low Pressure
Switch Error

While pumping down
refrigeration system, Low
Pressure Switch does not
trip for 6 minutes.

EC blinks.

Press
Reset
Button.

Refrigeration circuit,
Installation
conditions, Line
Valve, Pressure
Switch

EE

Gear Motor
Rotation
Error

During Gear Motor
operation, Rotation Sensor
stays ON for more than 5
seconds or OFF for more
than 20 seconds.

Whole unit
stops.

Press
Reset
Button.

Gear Head locked,
Gear Motor locked,
Rotation Sensor

EL

Spout Error

During Gear Motor
operation, Spout Switch
trips for 2 seconds (count

1), resets but trips again for
2 seconds within 5 minutes
after Gear Motor restarts
(count 2). “EL” appears on
count 1 (floor mounting) or
count 4 (fixed mounting).

Whole unit
stops.

Press
Reset
Button.

Ice Spout clogged,
Spout Switch, Bin
Control Switch

C1

Low Water

Float Switch does not trip at
upper float level for 20
minutes and unit shuts
down. “C1” appears
immediately (floor
mounting) or after 3
repetitions (fixed mounting).

Whole unit
stops.

Press
Reset
Button.

Water supply
interruption, Control
Water Valve not
opening, Flush
Water Valve not
closing, Float
Switch, Water leak

None

Electric Leak
Short Circuit

Electric leak or overcurrent.

Whole unit
stops.

Press
Reset
Button.
Replace
Fuse.

Electric leak, Fuse

Non-Interlock Errors

Code Error Condition Operation Reset Check/Repair

None

Stuck Float
Switch

During Compressor
operation, Float Switch
stays between upper and
lower float levels for 6
minutes (except for forced
drain or shutdown).

Forced water
supply.

N/A

Float Switch, Water
leak, Dirt in Tank

41

10

12

14

16

18

20

22

01234

AmbientTemp/WaterTemp(℃)

HeadPressure(bar)

1.2

1.4

1.6

1.8

2

2.2

2.4

SuctionPressure(bar)

HeadPressure(bar)
SuctionPressure(bar)

10/1021/1532/21

0

100

200

300

400

500

600

700

1月0日 1月1日 1月2日 1月3日 1月4日

AmbientTemp/WaterTemp(℃)

IceProductionCapacity(kg/day)

Thick

+10%

-10%

10/1021/1532/21

0

0.2

0.4

0.6

0.8

1

1月0日 1月1日 1月2日 1月3日 1月4日

AmbientTemp/WaterTemp(℃)

Waterconsumption(m

3

/day)

Thick

10/1021/153 2/21

10. PERFORMANCE DATA

[a] TM-500AAE (Thick Ice)

42

0

0.2

0.4

0.6

0.8

1

1月0日 1月1日 1月2日 1月3日 1月4日

AmbientTemp/WaterTemp(℃)

Waterconsumption(m

3

/day)

Thin

10/1021 /1532 /21

0

100

200

300

400

500

600

700

1月0日 1月1日 1月2日 1月3日 1月4日

AmbientTemp/WaterTemp(℃)

IceProductionCapacity(kg/day)

Thin

+10%

-10%

10/1021/1532/21

10

12

14

16

18

20

22

01234

AmbientTemp/WaterTemp(℃)

HeadPressure(bar)

1.2

1.4

1.6

1.8

2

2.2

2.4

SuctionPressure(bar)

HeadPressure(bar)
SuctionPressure(bar)

10/1021/1532/21

[b] TM-500AAE (Thin Ice)

43

IV. SERVICE DIAGNOSIS

Display error record by operating the Operation Board (See “III. 7. [b] 2) Displaying Error
Record”). Check for a possible cause and service the unit.

1. NO ICE PRODUCTION

PROBLEM POSSIBLE CAUSE REMEDY

1. OFF position. 1. Move to ON position.

2. Loose connections. 2. Tighten.

3. Bad contacts. 3. Check for continuity and
replace.

4. Blown fuse. 4. Replace.

a) Power Supply

5. Voltage too low. 5. Get recommended voltage.

b) Fuse (Controller

Board)

1. Blown out. No

indication on
Operation Board.

1. Find out the cause of short
circuit (ex. Control Water
Valve, Flush Water Valve),
resolve it, and replace
Controller Board.

1. OFF position. 1. Move to ON position. c) Operation Switch

2. Bad contacts. 2. Check for continuity and
replace.

d) Transformer 1. Coil winding opened. 1. Replace.
e) Water Valve 1. Coil winding opened. 1. Replace.

1. Closed. 1. Open. f) Water Supply Tap

2. Water failure. 2. Wait till water is supplied.

1. Disconnected. 1. Connect. g) Plug and

Receptacle
(Control Box)

2. Terminal out of Plug or

Receptacle.

2. Insert Terminal back in
position.

h) Spout Switch

(Proximity
Switch)

1. Tripped. 1. See “III. 6. [i] SPOUT
SWITCH”.

i) Overload

Protector

1. Tripped. 2. Reset.

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

2. Fixed mounting

selected by Select
Switch (floor
mounting).

2. Select the proper floor
mounting mode.

3. Dirty Sensor Cover. 3. Remove Switch and clean
or replace Sensor Cover.

[1] The icemaker

will not start.

j) Bin Control

4. No bin control hole in

mounting surface.

4. Move the unit and make a
hole.

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

a) Float Switch

2. Float does not move

freely.

2. Clean or replace.

b) Flush Water

Valve

1. Valve seat clogged

and water leaking.

1. Clean or replace.

[2] Water does not

stop, and the
icemaker will not
start.

c) Hoses 1. Disconnected. 1. Connect.

[3] Water has been

supplied, but the
icemaker will not
start.

a) Gear Motor

Protector
(Thermal
Breaker)

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

44

PROBLEM POSSIBLE CAUSE REMEDY

b) Controller Board 1. Broken. 1. Replace.

1. Dirty Condenser fins. 1. Clean.

2. Ambient temperature

too warm.

2. Check for recommended
temperature.

3. Fan not rotating. 3. See 3 - [1] - a).

4. Refrigerant
overcharged.

4. Recharge.

5. Refrigerant line or
components plugged.

5. Clean and replace Drier.

6. Bad contacts. 6. Check for continuity and

replace.

[3] (Continued)

c) Pressure Switch

7. Loose connections. 7. Tighten.

1. Loose connections. 1. Tighten.

2. Motor winding opened
or earthed.

2. Replace.

a) Gear Motor

3. Motor Protector
tripped.

3. Find out the cause of
overheat or overcurrent.

b) Power Supply 1. Circuit Ampacity too

low.

1. Install a larger-sized
conductor.

[4] Compressor

starts, but Gear
Motor will not
operate after 15
seconds.

c) Controller Board 1. Broken. 1. Replace

1. Gas leaks. 1. Check for leaks with a leak
detector. Reweld leak,
replace Drier and
Mechanical Seal, and
charge with refrigerant.
The amount of refrigerant is
marked on Nameplate or
Label.

a) Refrigerant Line

2. Refrigerant line

clogged.

2. Replace the clogged
component.

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

2. Loose connections. 2. Tighten.

[5] Gear Motor and

Compressor
start, but no ice
is produced.

b) Line Valve

3. Broken. 3. Replace.

2. LOW ICE PRODUCTION

PROBLEM POSSIBLE CAUSE REMEDY

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

2. Refrigerant line

clogged.

2. Replace the clogged
component.

a) Refrigerant Line

3. Overcharged. 3. Recharge.

1. Dirty Air Filter or
Condenser.

1. Clean.

2. Ambient temperature
too warm.

2. Check for recommended
temperature.

b) High-side

Pressure Too
High

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

c) Expansion Valve 1. Low-side pressure

exceeding the limit.

1. Adjust or replace.

[1] Low ice

production.

d) Evaporator 1. Evaporator deformed. 1. Replace.

45

3. OTHERS

PROBLEM POSSIBLE CAUSE REMEDY

1. Bearing worn out.

1. Replace.

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

a) Fan Motor

(Condenser Unit)

3. Fan blade does not
move freely.

3. Replace.

1. Bearings worn out, or
cylinder valve broken.

1. Replace.

b) Compressor

2. Mounting pad out of
position.

2. Reinstall.

c) Refrigerant Lines 1. Rub or touch lines or

other surfaces.

1. Replace.

d) Gear Motor (Ice

Making)

1. Bearing or Gear
wear/damage.

1. Replace.

e) Evaporator 1. Low-side pressure too

low.

1. See if Expansion Valve Bulb is
mounted properly, and
replace the valve if necessary.

f) Gear Head 1. Damaged. 1. Replace.

[1] Abnormal noise

g) Heater 1. Broken. 1. Replace.
a) Water Valve

1. Diaphragm does not
close.

1. Clean or replace.

[2] Overflow from

Tank (Water
does not stop.)

b) Float Switch

1. Bad contacts.

1. Check for continuity and
replace.

a) Power Supply

Voltage

1. Too high or too low.

1. Connect the unit to a power
supply of proper voltage.

[3] Gear Motor

Protector
operates
frequently.

b) Evaporator Assy 1. Bearing, Drum or

Gear Head worn out.

1. Replace Bearing, Drum or
Gear Head.

46

V. REMOVAL AND REP LACEMENT OF COMPONENTS

1. SERVICE FOR REFRIGERANT LINES

[a] SERVIC E INFORMATION

1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R404A]

The compressor must not be opened more than 30 minutes in replacement or service. Do
not mix lubricants of different compressors even if both are charged wi th the same refrigerant,
except when they use the same lubricant.

2) Treatment for Refrigerant Leak [R404A]

If a refrigerant leak occurs in the low side of an ice maker, air may be draw n in. Even if the low
side pressure is higher than the atmospheric pressure in normal operation, a continuous
refrigerant leak will eventually lower the low side pressure below the atmospheric pressure
and will cause a ir suction. Air contains a large amount of moisture, and ester oil easily a bsorbs
a lot of moisture. If an ice maker charged with R404A has possibly drawn in air, the drier
must be replaced. Be sure to use a drier designed for R404A.

3) Handling of Handy Flux [R404A]

Repair of the refrigerant circuit needs brazing. It is no problem to use the same handy flux
that has been used for the current refrigerants. However, its entrance into the refrigerant
circuit should be avoided as much as possible.

4) Oil for Processing of Copper Tubing [R40 4A]

When processing the copper tubing for service, wipe off oil, if any used, by using alcohol or
the like. Do not use too much oil or let it in to the tubing, as wax contained in the oil will clog the
capillary tubing.

5) Service Parts for R404A

Some parts used for refrigerants other than R404A are similar to those for R404A. But never
use any parts unl ess t hey ar e spec i f ied f or R404A be caus e t heir endura nc e ag ai nst t he
refrigerant have not been evaluated. Also, for R404A, do not use any parts that have been
used for other refrigerants. Otherwise, wa x and chlorine remaining on the parts may adversely
affect R404A.

6) Replacement Copper Tubing [R404A]

The copper tubes currently in use are suitable for R404A. But do not use them if oily inside.
The residual oil in copper tubes should be as little as possible. (Low residual oil type copper
tubes are used in the shipped units.)

47

7) Evacuation, Vacuum Pump and Refrigerant Charge [R404A]

Never allow the oil in the vacuum pump to flow backward. The vacuum level and vacuum
pump may be the same as those for the current refrigerants. However, the rubber hose and
gauge manifold to be used for evacuation and refrigerant charge should be exclusively for
R404A.

8) Refrigerant Leak Check

Refrigerant leaks can be detected by charging the unit with a little refrigerant, raising the
pressure with nitrogen and using an electronic detector. Do not use air or oxygen instead of
nitrogen for this purpose, or rise in pressure as well as in temperature may cause R404A to
suddenly react with oxygen and explode. Be sure to use nitrogen to prevent explosion.

[b] REFRIGER ANT RECOVERY

The refri geran t mus t be rec ov ered if re quire d by an appli ca ble law. A Low-side Ac c ess
V alve is provided in the unit. Recover the refrigerant from the Access Valve, and store it in a
proper container . Do not discharge the refrigerant into the atmosphere.
When replacing the Drier , take the opportunity to also fit a High-side Access V alve for ease
of charging liquid refrigerant.

[c] EVACUATION AND RECHARGE

1) Attach Charging Hoses, Service Manifold and V acuum Pump to the Low-side and High­side (to be fitted by servicer) Access Valves. If possible, use Quick Release Connectors
onto the Access Valves (especially on the high side).

2) Turn on the Vacuum Pump.

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

4) Close the Low- side and High-side Valves on the Service M anifold.

5) Disconnect the V acuum Pump, and attach a Refrigerant Charging Cylinder to accurately
weigh in the liquid charge. Remember to purge any air from the Charging Hose. See the
Nameplate for the re quired refriger ant cha rge.

6) Open the High-side V alve on the Gauge Manifold, and accurately measure in the liquid
charge. Close the valve on the Charging Cylinder before closing the High-side Manifold
V alve. Any remaining liquid in the line can be charged into the low side.

Note: Always charge in the liquid stage, as many refrigerants are blends and vapour

charging will affect the blend consistency (eg. R404A).

48

7) Turn on the icemaker. Release the High-side Access Connector, and allow pressure in
the charging line to slowly enter the low side of the system. Cap off the High-side Access
V alve. When pressure reduces on the low side, disconn ect the low side charging line
and cap off the Access Valve.

8) Always cap the Access Valves to prevent a refrigerant leak. Tighten the cap to a torque of

9.81 - 12.26 Nm.

9) Always thoroughly leak test all joints and valve caps.

10) Avoid charging large quantities of liquid into the low side in case of damage to the
Compressor.

Cap

Access V alve

Depressed

OPEN

2. BRAZING

DANGER

1. Refrigerant R404A itself is not flammable, explosive and poisonous. However,
when exposed to an open flame, R404A creates Phosgene gas, hazardous
in large amounts.

2. Always recove r the re frigeran t an d store it in a prope r containe r, if required
by an applicable law. Do not discharge the refrigerant into the atmosphere.

3. Do not use silver alloy or copper alloy containing Arsenic.

4. In it s li quid sta te , th e ref ri ger ant can c aus e fr os tb it e beca us e of the l ow
temperature.

49

3. COMPRESSOR

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened.
Do not replace the Drier until after all other repair or repl acement has been
made.

1) Disconnect the pow er source.

2) Remove the panels.

3) Remove the T erminal Cover on the Compressor, and disconnect the Compressor w iring.

4) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See “1 . [b] REFRIGER ANT RECO VERY”).

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

WARNING

When repairing a refrigerant system, be careful not to let the burner flame contact
any electrical wires or insulation.

6) Remove the Bolts and Rubber Grommets.

7) Slide and remove the Compressor. Unpack the new Compressor package. Install the
new Compressor.

8) Attach the Rubber Grommets of the previous Compressor.

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

10) Place the Compressor in position, and secure it using the Bolts and Washers.
1 1) Remove plugs from the Discharge, Suction and Access Pipes.

12) Braze the Access, Suction and Discharge Pipes (Do not change this order) with nitrogen
gas flowing at the pressure of 0.2 - 0.3 bar .

13) Install the new Drier (See "4. DRIER").

14) Check for leaks using nitrogen gas (10 bar) and soap bubbles.

50

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

16) Connect the T erminals to the Compressor, and replace the Terminal Cover in its correct
position.

17) Refit the panels in their correct position.

18) Connect the power source.

4. DRIER

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened.
Do not replace the Drier until after all other repair or repl acement has been
made.

1) Disconnect the pow er source.

2) Remove the panels.

3) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See “1 . [b] REFRIGER ANT RECO VERY”).

4) Remove the Drier using brazing equipment.

5) Install the new Drier with the arrow on the Drier in the direction of the refrigerant flow. Use
nitrogen gas at the pressure of 0.2 - 0.3 bar when brazing the tubings.

6) Check for leaks using nitrogen gas (10 bar) and soap bubbles.

7) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required
refrigerant cha rge (See “1 . [c] EVACUATION AND RECHAR GE”) .

8) Refit the panels in their correct position.

9) Connect the power source.

51

5. EXPANSION VALVE

IMPORTANT

Sometimes moisture in the refrigerant circuit exceeds the Drier capacity and
freezes up at the Expansion V alve. Always install a new Drier every time the
sealed refrigeration system is opened. Do not replace the D rier u ntil after all
other repair or replacement has been made.

1) Disconnect the pow er source.

2) Remove the panels.

3) Recover the refrigerant and store it in a proper container, if required by an applicable law

(See “1 . [b] REFRIGER ANT RECO VERY”).

4) Remove the Expansion V alve Bulb at the Evaporator outlet.

5) Disconnect the Expansion V alve using brazing equipment.

6) Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar .

WARNING

Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 100°C.

7) Install the new Drier (See "4. DRIER").

8) Check for leaks using nitrogen gas (10 bar) and soap bubbles.

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

refrigerant charge (See "1. [c] EVACUATION A ND RECH ARGE").

10) Attach the Bulb to the suction line. Be sure to secure the Bulb using a wire or clamp and
replace the insulation.

1 1) Refit the p anels in their correct position.

12) Connect the power source.

52

6. E VAP O R ATO R AS S E MB L Y

1) Push the Stop Button to drain the water in the T ank.

2) Disconnect the pow er source.

3) Remove the panels.

4) Unscrew and remove the following parts (see Fig. 1 - 3):
T ank Guide

Spout Switch
T ank Cover (C)
T ank Cover (A) with Heater (T ank)

T o completely disconnect it from the unit, loosen the closed end connector or cut the
wire.

T ank Cover (B) with Float Switch

T o completely disconnect it from the unit, loosen the closed end connector or cut the

wire. The Float Switch is also removable separately .
Ice Guide
Switch Plate
Ice Guide - Side

Not ne cessary to remov e. The othe r parts ar e still remov able w ith this p art in pla ce.
Belt Cover
Sensor Cover

After loosening the screws, remove the Sensor Cover by sliding it toward the back

of the unit. Otherw ise , the Sensor attached to the Sen sor C over may contact the

Sensor Plate and get damage d.
Sensor Plate

GEA R MOTOR (Fig . 3)

5) Release the Gear Motor together with the Ge ar Motor Bracket from the T ank, by removing
the three screw s and slightly lifting up the assembly . Remove the Belt.

Note: T o remove only the Belt for replacement, the three screw s on the Gear M otor Bracket

do not need to be removed but should only be loosened.

6) Remove the Gear Motor and the Motor Cover, if necessary . T o completely disconnect it
from the unit, loosen the closed end connector or cut the wire.

PULLEY ( Fig. 3 )

7) Loosen the Hexagon Socket Head Cap Screws, and remove the Pulleys.

53

Fig. 1

Fig. 2

Fig. 3

54

CUTTER (Fig. 4, 5)

8) Remove the Heater Holder (L).

9) Loosen the screws, and remove the Support - Cutter and Cutter . The Cutter is attached
with the Heater and Thermal Fuse. T o completely disconnect it from the unit, loosen the
closed end connector or cut the wire.

10) Be careful not to damage the Heater.
1 1) When refitting the Cutter, use the adjust screws at the front and top to adjust the space

from the Drum to 0.2 - 0.5 mm at an ambient temperature of 15 - 35°C. M e asure the
space across the three positions on the Dru m's circumference. To prev ent lo osening,
tighten the adjusted screws a further 90 degrees and fix them by double nuts.

Note: The following steps w ill require refrigerant gas recovery. Skip them if not needed.

T o facilitate servicing after refrigerant recovery , loosen the flare nuts on the joints
and the four downward screws on the T ank Bracket, and move the Tank assembly
onto a separate work table.
When reassembling, apply a sealant to the four downward screws on the Tank
Bracket.

12) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See "1. [b] REFRIGERANT RECOVERY").

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened.
Do not replace the Drier until after all other repair or repl acement has been
made.

Fig. 4 Fig. 5

55

HOUSING AND MECHANICAL SEAL (Fig. 6)

13) Remove the two Insulations and the seven screws securing the entir e Housing assembly.

14) Remove the Mechanical Seal, C-ring and Gasket.
Note: Do not damage the Shaft. Use a special tool to remo ve the C- ring.

15) Slowly loosen the two temporary screws on the Housing (B).
Note: Oil comes leaking out when the screws are loosened. Prepare waste cloth under

to receive the o il.

16) Remove the Mechanical Seal, Gasket, Housing - Seal and O-ring in this order .
Note: The Bearing side o f the Hou sing - Seal is filled with be aring gr ease. Use tap e to

protect the Shaft on the refrigerant side before removing the Housing Seal.

BEA R IN G N UT (Fig. 7)

17) Use a pin wrench to remove the Bearing Nut, while holding the rotary shaft on the Gear
Head with a hand for easy removal. When refitting, tighten the Bearing Nut to a torque of
1 13 - 13 7Nm.

Fig. 6

56

TANK ( Fig. 7 )

18) Remove the four Joint Shafts and the Tank Brackets to take off the Tanks (L), (R) a nd
(LO).

19) Remove the Side Boss (L) and Bearing from the Tank (L).

20) Remove the Side Boss (R), Mounts - Gear and Gear Head from the T ank (R).
Note: Be car eful not to lose the O-r ings in steps 19) and 20).

21) Remove the Cord Seals from the Tanks (L) and (R).

EVAPORATOR (Fig. 7)

22) Remove the V -rings and Drum Sides.
Note: Handle the Drum with care not to damage its surface and Shaft.

IMPORTANT

When reassembling, the following parts must not be reused but replaced with
new parts: Insulation, Mechanical Seal, Gasket, C-ring, O-ring, Oil Seal, Cord
Seal, V-ring, Plug and Label - Ban.

REASSEMBLY

23) Fit the V-ring w ith its rip facing the side of the T ank. Apply petrolatum (vaseline) on the rip
side of the assembled V -ring.

24) Handle the Drum w ith care not to damage its surface and Shaft.

25) Assemble the Side Bo sses (L) and (R) w ith their side hole s facing down .

26) T o install the Gear Head on the Tank (R), use screws having their threads coated with a
food grade sealant.

27) When assembling the Drive Shaft and Gear Head, grease the Shaft (Dow C orn ing G-

4500) before insertion.

28) Fit the Tank (Lo) securely into the grooves where the Cord Seals are applied.

29) After refitting the T anks (Lo), (L) and (R), Drum, Bearing and Gear Hea d, check the T anks
for wate r leaks for more tha n 2 minutes.

57

Fig. 7

30) Install the Oil Seals in the proper directions.

31) When fitting the Mechanical Seals, use a clean smooth cloth containing MEK or acetone
to lightly wipe off the anti-rust oil, and apply a refrigeration oil (Copeland CS20 ester oil)
to the mating surfaces, rubbe r parts and Shaft. D o not use a wa ste cloth to oil the ma ting
surfaces (to prevent gas leaks). Be careful not to let foreign matters into the refrigeration
circuit when assembling the Mechanical Seals.

32) After finishing assembly, fill the Bearing with grease (Dow Corning G-4500) from the
grease nipple. Remove the screw at the bottom of the Housing, and apply the grease
until it overflows.

33) Secure the Pulleys by using screws coated with a thread sealant.

34) Mount the Gear Motor on the Bracket, apply the Belt on the Gear Motor and Gear Head
Pulleys, and tighten the three bolts with a force of 20N.

35) T o oil the Housing (B), remove the Label - Ban and Plug, and fill a refrigeration oil (approx.
16 mL). Use the Plug coated with a sealant to refit the Housing (B), and attach the Label

- Ban (see Fig. 8).

Fig. 8

58

36) Aft er filling the oil, tu rn the Dru m about twenty times to smooth the mating surfaces of the
Mechanical Seals. Then, run a pressure resistance test at 1.5 - 2.0MPa to check for
leaks.

37) When replacing the Ice Guide - Side, attach the Label - PE on the contact surfaces of the
T anks (L) and (R) for material identification.

38) Secure the Ice Guide and Sw itch Plate together. Be sure to position the Ice Guide over
the Switch Plate.

39) Always replace the Drier.

40) Check for leaks using nitrogen gas (10 bar) and soap bubbles.

41) After finishing an airtightness test, attach the Insulations.

42) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required
refrigerant cha rge ( See "1. [c] EVACUATION AND R ECHAR GE").

IMPORTANT

The follow ing parts should be handled with care to protect their surfaces from
damage and foreign matter: Mechanical Seal, Gasket, O-ring, Oil Seal, Cord
Seal, V-ring.

43) Refit the panels in their correct position.

44) Connect the power source.

7. CONTROL WATER VALVE

1) Disconnect the pow er source.

2) Close the water supply tap.

3) Remove the panels.

4) Disconnect the Terminals from the Control Water Valve.

5) Remove the Cover - Reservoir Inlet from the Control Water Valve.

6) Loosen the Fitting Nut on the Control Water Valve Inlets, and remove the Control Water
V alve. Do not lose the Packings inside the Fitting Nut.

7) Install the new Control Water V alve.

59

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

9) Open the water supply tap.

10) Connect the power source.
1 1) Check for water leaks.

12) Refit the panels in their correct position.

8. FLUSH WATER VALVE

1) Close the water supply tap.

2) Remove the panels.

3) Push the S top Button, and after 9 minutes disconnect the pow er source.

4) Remove the Cover - Water V alve.

5) Remove the Clamp and disconnect the Hose from the Flush Water Valve.

Note : Wa te r ma y stil l re ma in in si de th e Ev a po r a to r. Be su re to dr a in th e w a te r in to the

Drain Pan.

6) Disconnect the Terminals from the Flush Water V alve.

7) Remove the Flush Water Valve.

8) Remove the Drain Pipe from the Flush Water Valve.

9) Connect the Drain Pipe to the new Flush Water V alve, and place the valve in position.

10) Connect the Hose to the Flush Water V alve, and secure it with the Clamp.
1 1) Pour water into the Tank, and check for w ater leaks on the Flush Water Valve.

12) Open the water supply tap.

13) Connect the power source.

14) Check for water leaks.

15) Push the S top Button, and make sure water is flushing.

16) Push the Ice Button.

60

17) Refit the panels in their correct position.

9. CONTROLLER BOARD

IMPORTANT

A single type Controller Board is supplied as a Service Board. Do not repair
any parts and electronic devices on the Co ntroller Boar d in the field. Rep lace
the whole board with a new Service Board.

1) Disconnect the pow er source.

2) Remove the Front Panel.

3) Remove screws and the Cover - Control Box (Lo).

4) Disconnect the Connectors and Board Support from the Controller Board.

5) Remove the Controller Board from the Control Box.

6) Install the new Controller Board and reassemble the Control Box in the reverse order of
the removal procedure.

7) Replace the Front Panel in its correct position.

8) Connect the power source.

10. LINE VALVE

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is opened.
Do not replace the Drier until after all other repair or repl acement has been
made.

1) Disconnect the pow er source.

2) Remove the panels.

3) Recover the refrigerant and store it in a proper container, if required by an applicable law
(See “1 . [b] REFRIGER ANT RECO VERY”).

61

4) Remove the Line V alve using brazing equipment.

5) Disconnect the coil from the new Line V alve.

6) Braze the new Line V alve with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar.

WARNING

Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 120°C.

7) Install the new Drier (See "4. DRIER").

8) Check for leaks using nitrogen gas (10 bar) and soap bubbles.

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

refrigerant cha rge ( See "1. [c] EVACUATION AND R ECHAR GE").

10) Refit the coil until it clicks to lock in place.
1 1) Refit the p anels in their correct position.

12) Connect the power source.