Hoshizaki America FD-1001MLH-C Service Manual

Hoshizaki America, Inc.

Hoshizaki

Modular Flaker

Models FD-1001MAH(-C)

“A Superior Degree

of Reliability”

www.hoshizaki.com

FD-1001MWH(-C) FD-1001MRH(-C) FD-1001MLH(-C)

SERVICE MANUAL

Number: 73159 Issued: 2-12-2010

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 3069

Attn: Hoshizaki Technical Support Department

Phone: 1-800-33-1940 Technical Support (770) 487-331 Fax: 1-800-843-1056 (770) 487-3360 E-mail: techsupport@hoshizaki.com

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.



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 ................................................................................................. 7

I. Specications ..................................................................................................................... 8

A. Icemaker ....................................................................................................................... 8

1. FD-1001MAH (air-cooled) ....................................................................................... 8

. FD-1001MAH-C (air-cooled) ................................................................................... 9

3. FD-1001MWH (water-cooled) ............................................................................... 10

4. FD-1001MWH-C (water-cooled) ............................................................................ 11

5. FD-1001MRH (remote air-cooled) ......................................................................... 1

6. FD-1001MRH-C (remote air-cooled) ..................................................................... 13

7. FD-1001MLH (low side, parallel rack system) ....................................................... 14

8. FD-1001MLH-C (low side, parallel rack system) ................................................... 15

B. Condenser Unit ........................................................................................................... 16

1. URC-5F ................................................................................................................. 16

II. General Information ......................................................................................................... 18

A. Construction ................................................................................................................ 18

1. FD-1001MAH(-C) (air-cooled) ............................................................................... 18

. FD-1001MWH(-C) (water-cooled) ......................................................................... 19

3. FD-1001MRH(-C) (remote air-cooled) ................................................................... 0

4. FD-1001MLH(-C) (low side, parallel rack system) ................................................ 1

5. Ice Making Unit ...................................................................................................... 

B. Sequence of Operation ............................................................................................... 3

1. Sequence Cycles and Shutdown .......................................................................... 3

a) Fill Cycle .......................................................................................................... 3

b) Ice Purge Cycle ............................................................................................... 3

c) Freeze Cycle .................................................................................................... 3

d) Drain Cycle ..................................................................................................... 3

e) Shutdown Cycle ............................................................................................... 4

. Sequence Flow Chart ............................................................................................ 5

C. Control Board ............................................................................................................. 6

1. Control Board Layout ............................................................................................ 7

. Features ................................................................................................................ 8

a) Low Water Safety ............................................................................................ 8

b) Ice Purge Cycle Bypass ................................................................................... 8

c) Freeze Timer .................................................................................................... 8

d) Drain Frequency .............................................................................................. 8

e) Bin Control Shutdown Delay ............................................................................ 8

f) High Voltage and Low Voltage Cut-outs ........................................................... 9

g) LED Lights and Alarm Safeties Chart .............................................................. 9

3. Alarm Safeties ....................................................................................................... 30

a) Low Water Safety (1-beep alarm) .................................................................... 30

b) Control Switch in the "DRAIN" Position (-beep alarm) ................................... 30

c) High Pressure Switch (3 & 4-beep alarms) ...................................................... 30

d) Freeze Timer (5-beep alarm) ........................................................................... 30

e) Low Voltage (6-beep alarm) ............................................................................ 30

f) High Voltage (7-beep alarm) ............................................................................. 31

g) Gear Motor (8-beep alarm) .............................................................................. 31

h) Bin Control (9-beep alarm) ............................................................................ 31

4. Controls and Adjustments ..................................................................................... 31

a) Default Dip Switch Settings ............................................................................. 31

b) Infrared Sensor Shutdown Delay (S1 dip switch 1, , & 3) .............................. 3

c) Drain Frequency Control (S1 dip switch 4) ...................................................... 3

d) Continuous Dispensing Timer (S1 dip switch 5 & 6) ........................................ 3

e) Bin Control Selector (S1 dip switch 7) ............................................................. 33

f) Mechanical Bin Control Shutdown Delay (S1 dip switch 8) .............................. 33

g) Factory Use (S1 Dip Switch 9 & 10) ................................................................ 33

D. Bin Control .................................................................................................................. 34

E. Float Switch ................................................................................................................ 34

III. Technical Information ..................................................................................................... 35

A. Water Circuit and Refrigeration Circuit ....................................................................... 35

1. FD-1001MAH(-C) (air-cooled) ............................................................................... 35

. FD-1001MWH(-C) (water-cooled) ......................................................................... 36

3. FD-1001MRH(-C) (remote air-cooled) ................................................................... 37

4. FD-1001MLH(-C) (low side, parallel rack system) ................................................ 38

B. Wiring Diagrams ......................................................................................................... 39

1. FD-1001MAH(-C), FD-1001MWH(-C), FD-1001MRH(-C) ..................................... 39

. FD-1001MLH(-C) .................................................................................................. 40

3. Sequence Wiring Diagram .................................................................................... 41

a) Fill Cycle. ........................................................................................................ 41

b) Ice Purge Cycle .............................................................................................. 4

c) Freeze Cycle ................................................................................................... 43

d) 1-in-1 Drain Cycle ........................................................................................... 44

e) 1-in-1 Drain Cycle ......................................................................................... 45

f) Infrared Sensor Shutdown ................................................................................ 46

g) Mechanical Bin Control Shutdown ................................................................... 47

h) Low Water Safety ............................................................................................ 48

i) High Pressure Switch ........................................................................................ 49

C. Performance Data ...................................................................................................... 50

1. FD-1001MAH (air-cooled) ..................................................................................... 50

. FD-1001MAH-C (air-cooled) ................................................................................. 51

3. FD-1001MWH (water-cooled) ............................................................................... 5

4. FD-1001MWH-C (water-cooled) ............................................................................ 53

5. FD-1001MRH (remote air-cooled) ......................................................................... 54

6. FD-1001MRH-C (remote air-cooled) ..................................................................... 55

7. FD-1001MLH (low side, parallel rack system) ....................................................... 56

8. FD-1001MLH-C (low side, parallel rack system) ................................................... 57

IV. Service Diagnosis .......................................................................................................... 58

A. Ice Production Check .................................................................................................. 58

B. Diagnostic Procedure ................................................................................................. 58

C. Control Board Check .................................................................................................. 61

D. Bin Control Check ....................................................................................................... 66

1. Infrared Sensor Check .......................................................................................... 66

. Mechanical Bin Control Check .............................................................................. 67

E. Float Switch Check and Cleaning ............................................................................... 69

1. Float Switch Check ................................................................................................ 69

. Float Switch Cleaning ............................................................................................ 69

F. Diagnostic Charts ........................................................................................................ 71

1. No Ice Production .................................................................................................. 71

. Low Ice Production ................................................................................................ 74

3. Other ..................................................................................................................... 75

V. Removal and Replacement of Components ................................................................... 76

A. Service for Refrigerant Lines ...................................................................................... 76

1. Refrigerant Recovery (except MLH model) ........................................................... 76

. Brazing .................................................................................................................. 77

3. Evacuation and Recharge (R-404A) (except MLH model) .................................... 77

4. Refrigerant Recovery, Evacuation, and Recharge - MLH Model (low side, parallel

rack system) .......................................................................................................... 78

B. Removal and Replacement of Compressor ................................................................ 79

C. Removal and Replacement of Expansion Valve......................................................... 80

D. Removal and Replacement of Evaporator Assembly Components ............................ 81

1. Upper Bearing Wear Check .................................................................................. 8

. Removal and Replacement of Cutter .................................................................... 8

3. Removal and Replacement of Extruding Head ..................................................... 83

4. Removal and Replacement of Auger .................................................................... 83

5. Removal and Replacement of Evaporator ............................................................ 84

6. Removal and Replacement of Mechanical Seal and Lower Housing ................... 85

7. Removal and Replacement of Gear Motor ............................................................ 86

E. Removal and Replacement of Air-Cooled Condenser ................................................ 87

F. Removal and Replacement of Water-Cooled Condenser ........................................... 88

G. Removal and Replacement of Water Regulating Valve - Water-Cooled Model ......... 89

H. Adjustment of Water Regulating Valve - Water-Cooled Model ................................... 90

I. Removal and Replacement of Fan Motor (air-cooled and remote air-cooled models) . 90 J. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.)

- Remote Air-Cooled Model ...................................................................................... 91

K. Removal and Replacement of Liquid Line Valve or Suction Line Valve - MLH Model

(low side, parallel rack system) ................................................................................. 9

L. Removal and Replacement of Evaporator Pressure Regulator (E.P.R.) MLH Model

(low side, parallel rack system) ................................................................................. 93

M. Removal and Replacement of Water Valves.............................................................. 93

1. Inlet Water Valve ................................................................................................... 93

. Drain Valve ............................................................................................................ 94

N. Removal and Replacement of Control Board ............................................................. 95

VI. Cleaning and Maintenance ............................................................................................ 96

A. Cleaning and Sanitizing Instructions ........................................................................... 96

1. Cleaning Solution .................................................................................................. 96

. Cleaning Procedure ............................................................................................... 96

3. Sanitizing Solution ................................................................................................. 98

4. Sanitizing Procedure - Initial .................................................................................. 98

5. Sanitizing Procedure - Final .................................................................................. 99

B. Maintenance ............................................................................................................. 100

C. Preparing the Icemaker for Long Storage ................................................................ 10

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 eventual damage caused by improper, incorrect, and unreasonable use.

To reduce the risk of death, electric shock, serious injury, or re, follow basic precautions including the following:

• Electrical connection must be hard-wired and must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, re, or severe damage to equipment.

• 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 UNIT MUST BE GROUNDED. Failure to properly ground this unit could result in death or serious injury.

• 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.

I. Specications

A. Icemaker

1. FD-1001MAH (air-cooled)

Awaiting Data

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

notice.

2. FD-1001MAH-C (air-cooled)

AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) COMPRESSOR 240 V 4.2 RLA 34 LRA GEAR MOTOR 120 V 3 FLA 1/4 HP FAN MOTOR 115 V 0.85FLA 1/15 HP OTHER 120 V 0.03A MAXIMUM FUSE SIZE 15 A MAX. HACR BREAKER (USA ONLY) 15 A MAX. CIRC. BREAKER (CANADA ONLY) 15 A MINIMUM CIRCUIT AMPACITY 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *940 (427) 890 (405) 855 (389) Reference without *marks 80 820 (373) 790 (358) 755 (344)

90 725 (330) *695 (317) 670 (304)

100 640 (292) 615 (280) *580 (265) SHAPE OF ICE Cubelet ICE QUALITY Approx. 80%, Ice (90/70°F, Conductivity 200 µs/cm) APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 1390 (4.8) 1320 (3.4) POTABLE WATER 86 (12) 113 (12) gal./24HR (gal./100 lbs.) EXTERIOR DIMENSIONS (WxDxH) 22" x 24" x 25-15/16" (560 x 610 x 658mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 176 lbs. ( 80 kg ), Shipping 205 lbs. ( 93 kg ) CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger ( 1/4 HP Gear Motor ) ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL N/A BIN CONTROL SYSTEM (PRIMARY) Photoelectric Sensor BIN CONTROL SYSTEM (SECONDARY) Mechanical Bin Control (Proximity Sw.) COMPRESSOR Hermetic, Model RS70-C1E-PFV CONDENSER Air-cooled, Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R-404A, 1 lb.12oz. (800g) DESIGN PRESSURE High 427 PSIG, Low 230 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-off Relay COMPRESSOR PROTECTION Internal Protector GEAR MOTOR PROTECTION Fuse (3A) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch and Timer ACCESSORIES -SUPPLIED Spare Fuse

-REQUIRED Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 187-253 V

AMBIENT TEMP. 45-100° F WATER SUPPLY TEMP. 45-90° F WATER SUPPLY PRESSURE 10-113 PSIG

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

notice.

3. FD-1001MWH (water-cooled)

Awaiting Data

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

notice.

4. FD-1001MWH-C (water-cooled)

Awaiting Data

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

notice.

5. FD-1001MRH (remote air-cooled)

Awaiting Data

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

notice.

1

6. FD-1001MRH-C (remote air-cooled)

AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) COMPRESSOR 240 V 4.2 RLA 34 LRA GEAR MOTOR 120 V 3 FLA 1/4 HP FAN MOTOR REMOTE 115 V 3A MAX OTHER 120 V 0.03A MAXIMUM FUSE SIZE 15 A MAX. HACR BREAKER (USA ONLY) 15 A MAX. CIRC. BREAKER (CANADA ONLY) 15 A MINIMUM CIRCUIT AMPACITY 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *930 (423) 895 (406) 860 (390) Reference without *marks 80 825 (375) 790 (360) 760 (345)

90 730 (332) *720 (326) 670 (306)

100 645 (294) 620 (282) *580 (263) SHAPE OF ICE Cubelet ICE QUALITY Approx. 80%, Ice (90/70°F, Conductivity 200 µs/cm) APPROXIMATE STORAGE CAPACITY N/A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 1449 (4.8) 1401 (3.6) POTABLE WATER 86 (12) 112 (12) gal./24HR (gal./100 lbs.) EXTERIOR DIMENSIONS (WxDxH) 22" x 24" x 25-15/16" (560 x 610 x 658mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 176 lbs. ( 80 kg ), Shipping 205 lbs. ( 93 kg ) CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

- REFRIGERATION Discharge line 1-1/16-12 UNF Fitting (#10 AEROQUIP) CIRCUIT Liquid line 5/8-18 UNF Fitting (#6 AEROQUIP) ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger ( 1/4 HP Gear Motor ) ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL N/A BIN CONTROL SYSTEM (PRIMARY) Photoelectric Sensor BIN CONTROL SYSTEM (SECONDARY) Mechanical Bin Control (Proximity Sw.) COMPRESSOR Hermetic, Model RS70-C1E-PFV CONDENSER Air-cooled Remote Condenser unit URC-5F Recommended EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Thermostatic Expansion Valve

Condensing Pressure Regulator on URC-5F

REFRIGERANT CHARGE R-404A, 4 lb.1oz. (1850g)

(Ice Maker: 2 lb. 3 oz., Cond. Unit: 1 lb. 14 oz. ) DESIGN PRESSURE High 427 PSIG, Low 230 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-off Relay COMPRESSOR PROTECTION Internal Protector GEAR MOTOR PROTECTION Fuse (3A) REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch and Timer ACCESSORIES -SUPPLIED Spare Fuse

-REQUIRED Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 187-253 V

AMBIENT TEMP. 45-100° F

WATER SUPPLY TEMP. 45-90° F

WATER SUPPLY PRESSURE 10-113 PSIG

7. FD-1001MLH (low side, parallel rack system)

Awaiting Data

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

notice.

8. FD-1001MLH-C (low side, parallel rack system)

Awaiting Data

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

notice.

AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker)

FAN MOTOR

115 V Total 1.3FLA 65W

EXTERIOR DIMENSIONS (WxDxH

) 21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 454 mm)

DIMENSIONS INCLUDING LEGS (WxDxH

) 24" x 18-1/8" x 32-13/16" (610 x 460 x 834 mm)

EXTERIOR FINIS

H Galvanized Steel

WEIGHT Net 61 lbs. ( 28 kg ) Shipping 68 lbs. ( 31 kg )

CONNECTIONS - ELECTRI

C Permanent - Connection

- REFRIGERANT Discharge Line 1-1/16"-12 UNF Fitting (#10 AEROQUIP)

Liquid Line 5/8"-18 UNF Fitting (#6 AEROQUIP)

CONDENSER Air-cooled, Fin and tube type

FAN MOTOR PROTECTIO

N Thermal Protection

REFRIGERANT CONTROL Condensing Pressure Regulator

REFRIGERANT CHARG

E R-404A 1 lb. 14 oz. (850g)

DESIGN PRESSURE High 467 PSIG

OPERATING CONDITIONS VOLTAGE RANGE 104 ~ 127 V

AMBIENT TEMP

. -20 ~ 122 °F

ACCESSORIES -SUPPLIED Leg 2 pcs

Hex. Head Bolt w/Washe

r 8 x 16 8 pcs

Hex. Nut 8 8 pcs

B. Condenser Unit

1. URC-5F

a) Specications

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

notice.

b) Dimensions

24"

(610 mm)

23-1/32"

(585 mm)

Unit: in. (mm)

18-1/8"

(460 mm)

17-1/8"

(435 mm)

14-9/16"

(370 mm)

19-11/16" (500 mm)

18-1/8"

(460 mm)

20-15/32" (520 mm)

21-15/16" (557 mm)

6/16" × 3/4" (10×20 mm) 4×2 (SLOTTED HOLES)

14-1/8"

(358 mm)

(380 mm)

14-15/16"

(398 mm)

15-11/16"

17-7/8"

(454 mm)

(380 mm)

14-15/16"

2-1/2"

(63 mm)

7/8" DIA. HOLE

(23 mm DIA.)

6-5/16"

(160 mm)

2-15/16" (75 mm)

II. General Information

A. Construction

1. FD-1001MAH(-C) (air-cooled)

Spout

Extruding Head Heater (FD-1001MAH-C)

Evaporator

Expansion Valve

Gear Motor

Inlet Water Valve

Mechanical Bin Control

Control Box

Fan Motor

Air-Cooled Condenser

Ice Chute

Compressor

Infrared Sensor

2. FD-1001MWH(-C) (water-cooled)

Extruding Head Heater (FD-1001MWH-C)

Evaporator

Expansion Valve

Gear Motor

Inlet Water Valve

Spout

Mechanical Bin Control

Control Box

Water Regulating Valve

Water-Cooled Condenser

Ice Chute

Compressor

Infrared Sensor

3. FD-1001MRH(-C) (remote air-cooled)

Extruding Head Heater (FD-1001MRH-C)

Evaporator

Expansion Valve

Gear Motor

Inlet Water Valve

Spout

Mechanical Bin Control

Control Box

Ice Chute

Infrared Sensor

Compressor

0

4. FD-1001MLH(-C) (low side, parallel rack system)

Extruding Head Heater (FD-1001MLH-C)

Evaporator

Expansion Valve

Gear Motor

Inlet Water Valve

Spout

Mechanical Bin Control

Control Box

Liquid Line Valve

Strainer

Evaporator Pressure Regulator

Ice Chute

Suction Line Valve

Infrared Sensor

1

5. Ice Making Unit

Extruding Head Heater (Cubelet Models Only)

Cutter

Extruding Head Upper Bearing

Allen Head Cap Screw

Auger

Cylinder

Insulation

Mechanical Seal

O-Ring

Housing-Lower Bearing

Spline Coupling

Allen Head Cap Screw

Hexagon Head Bolt

Gear Motor



B. Sequence of Operation

The steps in the sequence are as outlined below. This unit utilizes a control board to switch the components on and off as needed. When power is supplied, the power switch is in the "ON" position, and the control switch is in the "ICE" position, CB "POWER OK" LED comes on.

1. Sequence Cycles and Shutdown

a) Fill Cycle

"WTRIN" LED is on. WV energizes and ll cycle begins. UF/S closes and WV de-energizes. 30-second GM delay timer starts. If UF/S remains open during ll cycle longer than 90 seconds, WV remains energized, and a 1-beep alarm sounds.

b) Ice Purge Cycle

"GM" LED is on. 30-second GM delay timer terminates. GMR (X on CB), GM, GMPR, FM/FMR energize. 5-minute ice purge timer starts; GM runs for 5 minutes to clear any ice from the evaporator. To bypass, press the "SERVICE" button on the control board after GM starts. WARNING! Risk of electric shock. Care should be taken not to

touch live terminals.

Note: UF/S must be closed before GMR will energize.

c) Freeze Cycle

"COMP" and "GM" LEDs are on. 5-minute ice purge timer terminates. GMR (X on CB), GM, GMPR, and FM/FMR remain energized, CR (X1 on CB) and Comp energize (LLV and SLV energize on MLH models). As water in the evaporator cools, ice starts forming within 4 to 6 minutes. This time frame depends on the inlet water and ambient temperature conditions. UF/S and LF/S operate WV as needed to continue the ice making process. This continues until BC shuts down the icemaker or power is turned off to the unit.

d) Drain Cycle

(1) 1-in-1 Drain Cycle: DV energizes once every hour when the 1-in-1 drain cycle

is activated (S1 dip switch 4 is in the "OFF" position (factory default position)). GMR (X on CB), GM, GMPR, FM/FMR, CR (X1 on CB), and Comp continue. DV energizes for  seconds every hour. This setting is recommended for optimum icemaker performance. The 1-in-1 drain cycle allows any sediment to drain from the evaporator without interrupting the icemaking process.

(2) 1-in-12 Drain Cycle (optional): DV energizes once every 1 hours when the 1-in-1

drain cycle is activated (S1 dip switch 4 is in the on position (optional)). 1 hour drain cycle timer terminates, CR (X1 on CB) and Comp de-energize (LLV and SLV de-energize on MLH model), GMR (X on CB), GM, GMPR, and FM/FMR continue. The 5-minute ice purge timer begins. When the 5-minute ice purge timer terminates, GMR (X on CB), GM, GMPR, and FM/FMR de-energize. 10-minute DT begins, DV energizes. After 10-minute DT terminates, 1 hour drain cycle timer starts.

3

(3) Manual Drain: Manual drain is used when servicing evaporator components and

cleaning and sanitizing the unit. When the unit is making ice and the control switch is moved to the "DRAIN" position, there is a 3-second delay, then CR (X1 on CB) and Comp (LLV and SLV on MLH models) de-energize and the 5-minute ice purge timer begins. When the 5-minute ice purge timer terminates, GMR (X on CB), GM, GMPR, and FM/FMR de-energize. DV energizes to drain the evaporator and reservoir. To avoid the 5-minute shutdown delay, turn off the power supply, then move the control switch to the "DRAIN" position. Turn on the power supply. DV energizes to drain the evaporator and reservoir. DV de-energizes when the control switch is moved to the "ICE" position.

e) Shutdown Cycle

(1) Infrared Sensor: When power is supplied to the icemaker, the green LED on IS

turns on. The green LED remains on constantly. As ice lls the storage bin to the level of activating IS, IS yellow LED turns on (ashing or steady). The yellow LED ashes when ice is at the outer limit of its range and turns steady as ice nears. After the yellow LED turns on (ashing or steady), IS shutdown delay timer (S1 dip switch 1, , & 3) begins. For a typical dispenser unit application, a 100-second shutdown delay is recommended. When used with a standard Hoshizaki storage bin, any shutdown delay setting is acceptable. See "II.C.4.b) Infrared Sensor Shutdown Delay (S1 dip switch 1, , & 3)." Once IS shutdown delay timer terminates, CR (X1 on CB) and Comp (LLV and SLV on MLH models) de-energize and the 5-minute ice purge timer begins. When the 5-minute ice purge timer terminates, GMR (X on CB), GM, GMPR, and FM/FMR de-energize. See "II.D. Bin Control."

Note: If IS fails to shutdown the icemaker, MBC opens, CB shuts down the icemaker

and a 9-beep alarm sounds.

(2) Mechanical Bin Control: CB shuts down the entire unit within 10 seconds when

MBC opens (actuator paddle engaged), and sounds a 9-beep alarm. For further details, see "II.C.4.f) Mechanical Bin Control Shutdown Delay (S1 dip switch 8)" and "II.D. Bin Control."

Legend: BC–bin control; CB–control board; Comp–compressor;

CR–compressor relay; DT–drain timer; DV–drain valve; FM–fan motor; FMR–fan motor-remote; GM–gear motor; GMPR–gear motor protect relay; GMR–gear motor relay; IS–infrared sensor; LF/S–lower oat switch;

LLV–liquid line valve (MLH model); MBC–mechanical bin control;

SLV–suction line valve (MLH model); UF/S–upper oat switch; WV–inlet

water valve

4

2. Sequence Flow Chart

1-beep alarm continues

WV continues

GMR off

GM off

GMPR off

FM off

FMR off

When UF/S closes,

alarm resets and

. Ice Purge Cycle

starts.

90 seconds

Low Water Safety

90 sec. FT exceeded

1-beep alarm sounds

90 sec. PT begins

Rell

FT Maximum

90 seconds

3. Freeze Cycle

FD Sequence Flow Chart

1-in-1 drain cycle. DV opens for  seconds every hour

(S1 Dip Switch 4).

Icemaker status does not change.

terminates

UF/S open

WV on

exceeded

LF/S closed

UF/S closed

FT off (90 sec.)

UF/S open

LF/S open (WV on)

CR on

Comp on

FT exceeded

1-beep alarm sounds

CR off

Comp off

LLV off

SLV off

FT off

WV off

CR continues

Comp continues

GMR continues

GM continues

FT started (90 sec.)

WV on

CR continues

Comp continues

GMR continues

GM continues

LLV on

SLV on

GMR continues

GM continues

GMPR continues

FM continues

GMR continues

GM continues

GMPR continues

FM continues

FMR continues

GMPR continues

FM continues

FMR continues

FM continues

FMR continues

LLV continues

SLV continues

LLV continues

SLV continues

to ". Ice Purge Cycle" above

IS Green LED on

IS Yellow LED off

4. Icemaker Restart

3. Icemaker Off

4. Icemaker Restart

3. 10-Minute

5 minutes

2. Ice Purge Cycle

to "1. Fill Cycle" above

10-min. DT off (DC only)

DV off (DC only)

1-in-12 DT reset (DC only)

Drain

DV on (DC only)

GMR off

GM off

GMPR off

FM off

IS activated or

DC starts

CR off

Comp off

LLV off

FMR off

SLV off

GMR continues

GM continues

GMPR continues

FM continues

FMR continues

5 minutes

To bypass, press the

"SERVICE" button after

4. 1-in-12 Drain Cycle - Although the factory default 1-in-1 drain cycle

is recommended, a 1-in-1 drain cycle is available. For 1-in-1 drain

cycle sequence, see "3. 1-in-1 Hour Drain Cycle & Restart (optional)."

GM starts.

2. Ice Purge Cycle

1. Fill Cycle

Power Switch "ON"

30 sec.

Maximum

90 seconds

Control Switch in "ICE"

POWER OK LED on

IS Green LED on

IS Yellow LED off

1. Startup

GMR on

GM on

GMPR on

LF/S closed

UF/S closed

FT off

If Fill > 90 sec. FT

WV on

FT on (90 sec.)

FM on

FMR on

WV off

1-beep alarm sounds

WV continues

When UF/S closes

alarm resets and

5

. Ice Purge Cycle starts.

Note: If IS fails to shutdown the

2. Infrared Sensor Shutdown & Restart

1, , & 3

1. DT Initiates DC

IS Green LED on

1. Bin Full

icemaker, MBC opens and a

9-beep alarm sounds.

IS Yellow LED (ashing or steady)

IS delay determined by S1 dip switch

IS Green LED on

IS Yellow LED off

& Restart (optional)

(S1 dip switch 4)

3. 1-in-12 Drain Cycle

GMR-gear motor relay (X CB)

IS-infrared sensor bin control

LF/S-lower oat switch

LLV-liquid line valve (MLH only)

MBC-mechanical bin control

PT-purge timer

SLV-suction line valve (MLH only)

Legend:

Comp-compressor

CR-compressor relay

DC-drain cycle

DT-drain timer

DV-drain valve

FM-fan motor

FMR-fan motor-remote

UF/S-upper oat switch

WV-water valve

FT-ll timer (low water safety)

GM-gear motor

GMPR-gear motor protect relay

C. Control Board

• A Hoshizaki exclusive control board is employed in FD-1001MAH(-C), FD-1001MWH(-C), FD-1001MRH(-C), and FD-1001MLH(-C) Modular Flakers.

• All models are pre-tested and factory set.

CAUTION

1. The control board is fragile; handle very carefully.

. The control board contains integrated circuits, which are susceptible to

failure due to static discharge. It is especially important to touch the metal part of the icemaker before handling or replacing the control board.

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

4. Do not change wiring and connections. Never misconnect terminals.

5. Do not short out power supply to test for voltage.

6. Always replace the whole control board if it goes bad.

The control board provides the following safeguards:

• High and low voltage protection.

• Provides component protection during low water supply.

• Purges remaining ice in the evaporator.

• Provides short cycle protection for the compressor.

6

1. Control Board Layout

• "COMP" LED (X1 Relay)

• "GM" LED (X2 Relay)

GM FMR

FMS

Comp LLV SLV

"F-A" Control Board

• K9 Connector (5VDC)

Control Switch #1 & # (white/black)

High Pressure Switch #3 & #4 (yellow)

Gear Motor Protect Relay Circuit #5 & #6 (white/orange)

• S2 "SERVICE" Button (Ice Purge Cycle Bypass)

• K1 Connector

(115VAC)

#3 Input (black) # GM, FMR, FMS (brown)

• "FLUSH" LED

(X3 Relay) (drain)

• "WTRIN" LED

(X4 Relay)

• K2 Connector

(24VAC)

Drain Valve #10 (white/blue)

Transformer Input #9 (white/red)

Inlet Water Valve #8 (white/brown)

Transformer Input #7 (white/red)

• K8 Connector

(24VAC and 5VDC)

Transformer 4VAC Input #1 (white/red)

Transfomer 4VAC Neutral # (light blue)

Mechanical Bin Control #3 & #4 (gray) (5VDC)

Float Switch #5 (black) (5VDC)

Upper Float Switch #6 (red)

Lower Float Switch #7 (dark blue)

• K7 Connector-Open

• "POWER OK" LED

Water Dispensing Valve, Agitation Motor, and Ice Dispensing LEDs (not used on this model)

• J2 Connector-Open

• K3 Connector-Open

• K4 Connector-Open

• K5 Connector-Open

"F-A" Control Board

Part Number

A496-01

7

• S1 Dip Switch

• K6 Connector (20VDC) Infrared Sensor (brown (ground)) (white, signal (common)) (dark blue)

2. Features

a) Low Water Safety

When the inlet water valve opens during ll and rell, a 90-second low water safety timer starts. Once the upper oat switch closes the 90-second low water safety timer terminates. If the upper oat switch remains open longer than 90 seconds, a 1-beep alarm sounds. The water valve and 1-beep alarm continue until the upper oat switch closes.

b) Ice Purge Cycle Bypass

To speed up the diagnostic process, the 5-minute ice purge cycle may be bypassed by pressing the "SERVICE" button on the control board after the gear motor starts.

WARNING! Risk of electric shock. Care should be taken not to touch live terminals.

c) Freeze Timer

A 30-minute freeze timer starts once the upper oat switch closes. Should the upper oat switch fail to close again before the 30-minute timer terminates, the control board shuts down the icemaker and sounds a 5-beep alarm every 5 seconds. Also, when the lower oat switch is open and the upper oat switch is closed, the control board sounds a 5-beep alarm every 5 seconds. Both alarms require a manual reset. For further details, see "II.C.3.d) Feeze Timer (5-beep alarm)."

d) Drain Frequency

(1) 1-in-1 Drain Cycle: The 1-hour drain timer terminates, then the drain valve energizes

for  seconds. This occurs once every hour when the 1-in-1 drain cycle is activated (S1 dip switch 4 in the "OFF" position (factory default)). This setting is recommended for optimum icemaker performance. The 1-in-1 drain cycle allows for maximum drainage of any sediment from the evaporator without interrupting the icemaking process.

(2) 1-in-12 Drain Cycle (optional): The 1-hour drain timer terminates, then the

icemaker cycles down and the drain valve energizes for 10 minutes. This occurs once every 1 hours when the 1-in-1 drain cycle is activated (S1 dip switch 4 in the "ON" position (optional)). For further details, see "II.B.1.d) Drain Cycle."

e) Bin Control Shutdown Delay

(1) Infrared Sensor: The ice level at shutoff may need to be adjusted depending on the

dispenser agitation or dispense method. For a typical dispenser unit application, a 100-second shutdown delay is recommended. Increasing the shutdown delay setting allows for a higher level of ice in the bin before the icemaker shuts down. When used with a standard Hoshizaki storage bin, any shutdown delay setting is acceptable. For further details, see "II.C.4.b) Infrared Sensor Shutdown Delay (S1 dip switch 1, , and

3)."

(2) Mechanical Bin Control: The control board shuts down the entire unit within

10 seconds when the mechanical bin control proximity switch opens (actuator paddle engaged). For further details, see "II.C.4.f) Mechanical Bin Control Shutdown Delay (S1 dip switch 8)."

8

f) High Voltage and Low Voltage Cut-outs

The maximum and minimum allowable supply voltages of this icemaker are limited by the high voltage (147Vac±5% or more) and low voltage (9Vac±5% or less) cut-outs.

When high voltage (147Vac±5% or more) is present, the icemaker automatically stops and the control board signals with a 7-beep alarm every 3 seconds.

When low voltage (9Vac±5% or less) is present, the icemaker automatically stops and the control board signals with a 6-beep alarm every 3 seconds.

When the proper supply voltage is resumed, the icemaker automatically starts running again.

g) LED Lights and Alarm Safeties Chart

The "POWER OK" LED indicates proper control voltage and will remain on unless a control voltage problem occurs. For further details, see "II.B. Sequence of Operation."

Sequence Step LED

Fill Cycle WTRIN WV - Ice Purge Cycle GM GM, FM/FMR 5 min. 5 min. Freeze Cycle (with rell) GM, WTRIN* (rell),

COMP

Drain Cycle FLUSH (Drain) DV  sec. 10 min.

Energized

Components Min. Max.

GM, Comp, FM/FMR, LLV, SLV, WV* (rell)

- *On until UF/S closes. Alarm sounds after 90 sec.

The built-in alarm safeties shut down the unit.

No. of Beeps

(every 5 sec.)

1 Low Water Safety

UF/S open > 90 seconds after WV energized.

 Control Switch

In "DRAIN" position longer than 15 minutes.

3 High Pressure Switch

First and second activation in 1 hour.

4 High Pressure Switch

Third activation in 1 hour.

5 Freeze Timer

WV off > 30 minutes since last WV activation.

6 Low Voltage

(9Vac ±5% or less)

7 High Voltage

(147Vac ±5% or more)

8 Gear Motor

GMPR contacts fail to close.

9 Infrared Sensor (S1 dip switch 7)

MBC actuator paddle engaged.

Type of Alarm Reset Options

Automatic reset once water supply is restored and UF/S closes.

Automatic reset once the control switch is moved to the "ICE" position.

Automatic reset once pressure drops below the high pressure threshold and the high pressure switch closes.

Call for service. To avoid possible catastrophic failure, it is recommended to leave the icemaker off until this alarm is resolved. Manual reset. Turn power off and on again.

Manual reset. Turn power off and on again.

"POWER OK" LED turns off if voltage protection operates. The control voltage safeties automatically reset when voltage is corrected.

Manual reset. Turn power off and on again.

Legend: Comp–compressor; DV–drain valve; FM–fan motor; FMR–fan motor-remote;

GM–gear motor; GMPR–gear motor protect relay; LLV-liquid line valve (MLH model only); MBC–mechanical bin control; SLV–suction line valve (MLH model only); UF/S–oat switch; WV–inlet water valve

9

3. Alarm Safeties

a) Low Water Safety (1-beep alarm)

(1) Fill Cycle: If upper oat switch remains open 90 seconds after the inlet water valve

has energized, the control board sounds a 1-beep alarm every 5 seconds. The alarm resets and the icemaker automatically starts running again once water is restored or the oat switch is cleaned or replaced.

(2) Freeze Cycle/Rell: If upper oat switch remains open 90 seconds after the inlet

water valve energizes, the compressor de-energizes and the control board sounds a 1-beep alarm every 5 seconds. The gear motor continues for another 90 seconds to clear the ice from the evaporator. The inlet water valve and 1-beep alarm continue until the upper oat switch closes. The alarm resets and the icemaker automatically starts running again when the upper oat switch closes.

b) Control Switch in the "DRAIN" Position (2-beep alarm)

When the control switch is left in the "DRAIN" position longer than 15 minutes, the control board sounds a -beep alarm every 5 seconds. When the control switch is moved to the "ICE" position, the alarm resets and the icemaker starts running again.

c) High Pressure Switch (3 & 4-beep alarms)

(1) 3-beep alarm: For the rst and second high pressure switch activation in 1 hour,

the icemaker shuts down and the control board sounds a 3-beep alarm every 5 seconds. When the high pressure switch closes, the alarm resets and the icemaker automatically starts running again.

(2) 4-beep alarm: For the third high pressure switch activation in 1 hour, the icemaker

shuts down and the control board sounds a 4-beep alarm every 5 seconds. This alarm is to prevent catastrophic failure to the compressor and requires a manual reset. Before resetting, contact your local Hoshizaki Service Representative. Turn the power off and then on again to reset the alarm. If the high pressure switch has reset, the icemaker starts running again.

d) Freeze Timer (5-beep alarm)

The control board starts a 30-minute freeze timer once the upper oat switch closes. As the water level drops in the reservoir, the upper oat switch opens. Should the upper oat switch fail to close again before the 30-minute freeze timer terminates, the control board sounds a 5-beep alarm every 5 seconds. This alarm requires a manual reset. Turn the power off and then on again to reset the alarm. The icemaker starts running. Also, when the lower oat switch is open and the upper oat switch is closed, the control board sounds a 5-beep alarm every 5 seconds. This alarm requires a manual reset. Turn the power off and then on again to reset the alarm. For further details, see "IV.E. Float Switch Check."

e) Low Voltage (6-beep alarm)

The minimum allowable power supply voltage of this icemaker is limited by the low voltage cut-out. When low voltage (9Vac ±5% or less) is present, the "POWER OK" LED turns off and the control board shuts down the unit and sounds a 6-beep alarm every 5 seconds. When the proper supply voltage resumes, the icemaker automatically starts running again.

+ 73 hidden pages