Hoshizaki America FD-1001MLH-C Service Manual

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Page 1

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

Page 2

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.



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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

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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

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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

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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

Page 7

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.

Page 8

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.

Page 9

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.

Page 10

3. FD-1001MWH (water-cooled)

Awaiting Data

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

notice.

Page 11

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

Awaiting Data

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

notice.

Page 12

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

Page 13

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

Page 14

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.

Page 15

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.

Page 16

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.

Page 17

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)

Page 18

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

Page 19

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

Page 20

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

Page 21

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

Page 22

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



Page 23

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

Page 24

(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

Page 25

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

Page 26

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

Page 27

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)

Page 28

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

Page 29

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

Page 30

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.

Page 31

f) High Voltage (7-beep alarm)

The maximum allowable supply voltage for this icemaker is limited by the high voltage cut-out. When high voltage (147.5Vac ±5% or more) is present, the "POWER OK" LED turns off and the control board shuts down the unit and sounds a 7-beep alarm every 5 seconds. When the proper supply voltage resumes, the unit automatically starts running again.

g) Gear Motor (8-beep alarm)

Gear motor operation is conrmed through the gear motor protect relay (control board K1 connector). If the white/orange (W/O) wires on the control board K9 connector (gear motor protect circuit) do not have continuity (gear motor protect relay de-energized), the compressor relay does not energize. If the icemaker is running, and the gear motor protect relay de-energizes, the control board shuts down the compressor and gear motor and sounds an 8-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. The compressor starts running again when the gear motor protect relay energizes. For further details, see "IV.B. Diagnostic Procedure."

h) Bin Control (9-beep alarm)

This alarm provides protection to prevent the icemaker from overlling the ice storage bin. If the infrared sensor is signifying the ice storage bin is empty (yellow LED off), and the mechanical bin control is signifying the ice storage bin is full (proximity switch open), the control board shuts down the unit and sounds a 9-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.D. Bin Control Check."

4. Controls and Adjustments

CAUTION

Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. For more information, contact Hoshizaki Technical Support at 1-800-33-1940.

a) Default Dip Switch Settings

The S1 dip switch settings are factory-set to the following positions:

Dip Switch No. 1 2 3 4 5 6 7 8 9 10

FD-1001M_H(-C) ON OFF OFF OFF OFF OFF ON ON OFF OFF

Normally off (factory use)

Mechanical Bin Control Shutdown Delay

Bin Control Selector

Continuous Dispensing Timer (DCM models only, do not adjust on modular icemakers)

Drain Frequency Control

Infrared Sensor Shutdown Delay

Page 32

b) Infrared Sensor Shutdown Delay (S1 dip switch 1, 2, & 3)

Infrared sensor shutdown delay is the delay between the infrared sensor detecting ice (yellow LED ashing or steady) and the start of the shutdown sequence. For dispenser unit applications, the ice level at shutoff may need to be adjusted depending on the dispenser agitation or dispense method. Increasing the shutdown delay setting allows for a higher level of ice in the bin before the icemaker shuts down. For a typical dispenser unit application, a 100-second shutdown delay is recommended. When used with a standard Hoshizaki storage bin, any shutdown delay setting is acceptable.

WARNING

Increasing the shutdown delay allows a higher level of ice in the dispensing unit/storage bin before shutdown. This could lead to icemaker movement or ice overow.

S1 Dip Switch Setting

No. 1 No. 2 No. 3

OFF OFF OFF 0 Seconds

ON OFF OFF 100 Seconds (1.6 minutes) (Factory Default)

OFF ON OFF 1100 Seconds (18.3 minutes)

OFF OFF ON 1650 Seconds (7.5 minutes)

ON ON OFF 00 Seconds (36.7 minutes)

OFF ON ON 0 Seconds

ON ON ON 0 Seconds

Infrared Sensor Shutdown Delay

c) Drain Frequency Control (S1 dip switch 4)

This unit is factory set for optimum performance with the 1-in-1 drain cycle (S1 dip switch 4 in the "OFF" position). This setting allows for removal of sediment from the evaporator without interrupting the icemaking process. An optional 1-in-1 drain cycle is available.

S1 Dip Switch Setting

No. 4

OFF (1-in-1) 1 Hour  Seconds

ON (1-in-1)

Drain Timer Interval Drain Valve Open

11 Hours 45 Minutes 10 Minutes

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

DCM models only. The dispense mode switch on DCMs must be in the "CONTINUOUS" position for this setting to apply. The factory setting allows ice to be dispensed continuously as long as the dispense solenoid is activated.

S1 Dip Switch Setting

No. 5 No. 6

OFF OFF No Limit

ON OFF 0 Seconds

OFF ON 60 Seconds

ON ON No Limit

Dispense Time

3

Page 33

e) Bin Control Selector (S1 dip switch 7)

This unit is factory set for infrared sensor bin control operation. No adjustment is required. When used on a standard ice storage bin, the mechanical bin control may be used instead of the infrared sensor by moving S1 dip switch 7 to the off position. In the factory default position (S1 dip switch 7 in the on position), the gear motor delay after the upper oat switch closes is 30 seconds. When the mechanical bin control is used (S1 dip switch 7 in the off position), the gear motor delay after the upper oat switch closes is 5 seconds. WARNING! Do not place S1 dip switch 7 in the off position on dispenser

unit applications.

S1 Dip Switch

Setting

No. 7

OFF Mechanical Bin Control (Standard Ice Storage Bins Only) 5 seconds

Infrared Sensor with Mechanical Bin Control Backup

Bin Control Application Gear Motor Delay

30 seconds

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

Factory set for normal operation. No adjustment is required. The shutdown delay is the time between the mechanical bin control proximity switch opening and the control board shutting off the icemaker.

S1 Dip Switch

Setting

No. 8

OFF 0.5 Seconds

ON 6.7 Seconds

Bin Control #1

Shutdown Delay

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

Factory set for optimum performance. Do not adjust.

Page 34

D. Bin Control

An infrared sensor is used to control the level of ice in the dispenser unit/ice storage bin (S1 dip switch 7 in the "ON" position). The infrared sensor is the primary bin control device. 0VDC powers the infrared sensor from the control board K6 connector. A green power LED and a yellow ice detection LED are located on the infrared sensor. See Fig. 1. The paddle-actuated mechanical bin control is used as a backup bin control and safety device. See Fig. . For further details, see "IV.D. Bin Control Check."

The paddle-actuated mechanical bin control may be used as a stand-alone bin control when the unit is placed on a standard Hoshizaki ice storage bin (S1 dip switch 7 in the off position). WARNING! Do not place S1 dip switch 7 in the off position on

dispenser unit applications.

Infrared Sensor Connector (0V DC from K6 connector on control board)

Infrared Sensor LED

Infrared Sensor

Infrared Sensor Housing

Fig. 1

Infrared Sensor LED

Infrared Sensor Lens

Ice Chute

Fig. 2

Proximity Switch

Actuator Paddle

E. Float Switch

A dual oat switch is used to determine that there is sufcient water in the reservoir during ll and rell. The control board monitors the upper oat switch to de-energize the inlet water valve when the upper oat switch closes during ll and rell. The control board monitors the lower oat switch to energize the inlet water valve when the lower oat switch opens during the freeze cycle (rell). See Fig. 3. The control board monitors the time between the lower oat switch opening and the upper oat switch closing (90-second low water safety). The control board also monitors the time between the upper oat switch closing and the lower oat switch opening (30-minute freeze timer). No adjustment is required. For a oat switch check procedure, see "IV.E.1. Float Switch Check."

Red (R) (upper ﬂoat switch)

Black (BK) (common)

Dark Blue (DBU) (lower ﬂoat switch)

Upper Float Switch (blue)

Spring Retainer Clip

Lower Float Switch (white)

Plastic Retainer Clip

Fig. 3

Page 35

III. Technical Information

A. Water Circuit and Refrigeration Circuit

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

Inlet

Water

Valve

Float

Water Supply Line

Switch

Water Level

Spout

Insulation

Drain Outlet

Condenser

Reservoir

Overow

Evaporator

Gear Motor

Drain Pan

Drier

Condenser Fan Motor

Expansion Valve

Drain Valve

Pressure Switch

Access Valve

Compressor

Water Circuit

Refrigerant Circuit

Page 36

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

Inlet Water Valve

Float

Water Supply Line

Switch

Spout

Insulation

Water Level

Drain Outlet

Cond. Water Inlet

Cond. Water Outlet

Reservoir

Overow

Evaporator

Gear Motor

Drier

Condenser

Expansion Valve

Drain Valve

Drain Pan

Pressure Switch

Access Valve

Water Regulating Valve

Access Valve

Compressor

Water Circuit

Refrigerant Circuit

Page 37

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

Inlet

Water

Valve

Float Switch

Water Supply Line

Water Level

Spout

Insulation

Drain Outlet

Reservoir

Overow

Condenser Unit

Condenser

Evaporator

Gear Motor

Drain Pan

Coupling

Insulation

Condensing Pressure Regulator (Headmaster)

Condenser Fan Motor

Pressure Switch

Expansion Valve

Drain Valve

Drier

Fusible Plug

Receiver Tank

Insulation

Coupling

Access Valve

Compressor

Water Circuit

Refrigerant Circuit

Page 38

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

Inlet Water Valve

Float

Water Supply Line

Switch

Water Level

Spout

Insulation

Drain Outlet

Reservoir

Overow

Evaporator

Gear Motor

Access Valve

Drain Pan

Expansion Valve

Drain Valve

Heat Exchanger

Liquid Line Valve

Strainer

Multi-Rack Condensing Unit

Access Valve

Water Circuit

Refrigerant Circuit

Suction Line Valve

Evaporator Pressure Regulator Valve (EPR Valve)

Page 39

B. Wiring Diagrams

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

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

R RED BK BLACK BR BROWN O ORANGE Y YELLOW GR GREEN GY GRAY P PINK V VIOLET W WHITE LBU LIGHT BLUE DBY DARK BLUE W/BU WHITE / BLUE W/R WHITE / RED W/BK WHITE / BLACK W/BR WHITE / BROWN W/0 WHITE / ORANGE

Page 40

2. FD-1001MLH(-C)

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 41

3. Sequence Wiring Diagram

a) Fill Cycle.

Power supply is turned on. Inlet water valve energizes and reservoir lls.

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 42

b) Ice Purge Cycle

Upper oat switch closes, 30-second gear motor delay timer starts. After 30-second gear motor delay timer terminates, 5-minute ice purge timer starts, gear motor, fan motor/ fan motor-remote energize.

Note: The 30-second gear motor delay is active when S1 dip switch 7 is in the on

position. Otherwise, gear motor has a 5-second delay when upper oat switch closes.

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

4

Page 43

c) Freeze Cycle

5-minute ice purge timer terminates, compressor energizes (liquid line valve, and suction line valve on MLH models).

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 44

d) 1-in-1 Drain Cycle

Compressor, (liquid line valve, suction line valve on MLH models), fan motor/fan motor-remote, and gear motor continue. Drain valve energizes for  seconds every hour.

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 45

e) 1-in-12 Drain Cycle

1-in-1 drain cycle initiates (S1 dip switch 4). Compressor and fan motor/fan motor-remote de-energize. 5-minute ice purge timer starts and gear motor continues. 5-minute ice purge timer terminates, gear motor de-energizes. Drain valve opens for 10 minutes.

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 46

f) Infrared Sensor Shutdown

Ice lls storage bin to level of activating infrared sensor, infrared sensor yellow LED turns on (ashing or steady). Infrared sensor shutdown sequence begins. For further information, see "II.B.1.e) Shutdown Cycle."

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 47

g) Mechanical Bin Control Shutdown

Ice lls the chute to the point of engaging the mechanical bin control. Dip Switch 7 "ON": The icemaker shuts down within 10 seconds of the mechanical bin control opening and a 9-beep alarm sounds. Dip Switch 7 "OFF": Hoshizaki ice storage bin applications only. The icemaker shuts down within 10 seconds of the mechanical bin control opening.

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 48

h) Low Water Safety

During ll or rell, should the upper oat switch fail to close within 90 seconds after the water valve energizes, a 1-beep alarm sounds. The water valve remains open until the upper oat switch closes. If this occurs during rell, the icemaker cycles down.

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH CONTROL

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 49

i) High Pressure Switch

If pressure on the refrigeration circuit high-side exceeds Hoshizaki specications, a high pressure switch activates. The control board then shuts down the unit until the high-side pressure returns to an acceptable level. See "II.C.3.c) High Pressure Switch (3 & 4-beep alarms)."

CONTROL BOARD

S1 SERVICE BUTTON

DIP SWITCH CONTROL

S X1 COMPRESSOR RELAY

WIRE COLOR CODE

Page 50

C. Performance Data

1. FD-1001MAH (air-cooled)

Awaiting Data

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

notice.

Page 51

APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F) PER 24 HR. 70

*940 *(427)

890

(405)

855

(389)

80 820

(373)

790

(358)

755

(344)

90 725

(330) *695 *(317)

670

(304)

lbs./day (kg/day) 100 640

(292)

615

(280) *580 *(265)

APPROXIMATE ELECTRIC 70

*1404

-- 1402 -- 1400 --

CONSUMPTION 80 1398 -- 1395 -- 1393 --

90 1391 --

*1389

-- 1372 --

watts 100 1354 -- 1337 --

*1319

APPROXIMATE WATER 70

*113 *(427)

107

(405)

103

(389)

CONSUMPTION PER 24 HR. 80 99

(373)

(358)

(344)

90 87

(330) *84 *(317)

(304)

gal./day (l/day)

100 77

(292)

(280) *70 *(265)

EVAPORATOR OUTLET TEMP. 70

*17 *(-9)

(-9)

80 17

(-9)

(-10)

90 14

(-10) *14 *(-10)

(-11)

°F (°C) 100 12

(-11)

(-11) *12 *(-11)

HEAD PRESSURE 70

*304 *(21.4)

304

(21.4)

304

(21.4)

80 287

(20.1)

287

(20.1)

287

(20.1)

90 269

(18.9) *269 *(18.9)

269

(18.9)

PSIG (kg/cm²G)

100 204

(14.3)

204

(14.3) *204 *(14.3)

SUCTION PRESSURE 70

*39 *(2.7)

(2.7)

80 37

(2.6)

90 36

(2.5) *36 *(2.5)

(2.5)

PSIG ( kg/cm²G )

100 31

(2.2)

(2.2) *31 *(2.2)

TOTAL HEAT OF REJECTION 8800 BTU/h (AT 90°F /WT 70°F)

50 70 90

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

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

notice.

Page 52

3. FD-1001MWH (water-cooled)

Awaiting Data

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

notice.

5

Page 53

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

Awaiting Data

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

notice.

Page 54

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

Awaiting Data

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

notice.

Page 55

APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F) PER 24 HR. 70

*930

*(423) 895

(406)

860

(390)

80 825 (375) 790

(360)

760

(345)

90 730

(332)

*720

*(326)

670

(306)

lbs./day (kg/day) 100 645

(294)

620

(282) *580 *(263)

APPROXIMATE ELECTRIC 70

*1401

-- 1408 -- 1415 --

CONSUMPTION 80 1422 -- 1428 -- 1435 --

90 1442 --

*1449

-- 1444 --

watts 100 1440 -- 1435 --

*1430

APPROXIMATE WATER 70

*112 *(423)

108

(406)

103

(390)

CONSUMPTION PER 24 HR. 80 99

(375)

(360)

(345)

90 88

(332) *86 *(326)

(306)

gal./day (l/day)

100 78

(294)

(282) *70 *(263)

EVAPORATOR OUTLET TEMP. 70 *5 *(-15) 5 (-15) 5 (-15)

80 5 (-15) 9

(-13)

90 9

(-13)

*(-13)

(-11)

°F (°C) 100 12

(-11)

(-11) *12 *(-11)

HEAD PRESSURE 70 *205

*(14.4)

205

(14.4)

205

(14.4)

80 234 (16.5) 234 (16.5) 234 (16.5)

90 264

(18.6) *264 *(18.6)

264

(18.6)

PSIG (kg/cm²G)

100 301 (21.1) 301 (21.1) 301 *(21.1)

SUCTION PRESSURE 70 *33

*(2.3)

33 (2.3) 33 (2.3)

80 35 (2.4) 35 (2.4) 35 (2.4) 90 36

(2.6) *36 *(2.6)

(2.6)

PSIG ( kg/cm²G )

100 39

(2.7)

(2.7) *39 *(2.7)

CONDENSER VOLUME 74.5 cu in HEAT OF REJECTION FROM CONDENSER 8900 BTU/h (AT 90°F /WT 70°F) HEAT OF REJECTION FROM COMPRESSOR 1400 BTU/h (AT 90°F /WT 70°F)

50 70 90

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

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

notice.

Page 56

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.

Page 57

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.

Page 58

IV. Service Diagnosis

WARNING

1. This unit should be diagnosed and repaired only by qualied service personnel to reduce the risk of death, electric shock, serious injury, or re.

. Risk of electric shock. Use extreme caution and exercise safe electrical

practices.

3. Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.

4. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the unit is serviced. Make sure that none have fallen into the dispenser unit/storage bin.

5. Make sure all food zones in the icemaker and dispenser unit/storage bin are clean after the unit is serviced. For cleaning procedures, see "VI. Cleaning and Maintenance."

A. Ice Production Check

To check production, prepare a bucket or pan to catch the ice and a set of scales to weigh the ice. After the icemaker has operated for 10 to 0 minutes, catch the ice production for 10 minutes. Weigh the ice to establish the batch weight. Multiply the batch weight by 144 for the total production in 4 hours.

B. Diagnostic Procedure

This diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components. Before proceeding, check for correct installation, adequate water supply (minimum of 10 PSIG, maximum of 113 PSIG) and proper voltage per unit nameplate. Check that the 4VAC 1A fuse and the 115VAC 3A GM fuse are good. When checking for high-voltage (115VAC), always choose a white (W) neutral wire to establish a good neutral connection. When checking for low-voltage (secondary) (4VAC), always choose a light blue (LBU) neutral wire to establish a good neutral connection. If the icemaker is in alarm, see "II.C.3. Alarm Safeties."

Note: FM/FMR and EHH (-C model only) energize when "GM" LED turns on. On MLH

model, CB X1 Comp relay energizes LLV and SLV.

1) Turn off the power supply.

) Remove the front panel, then move the power switch to the "OFF" position.

3) Remove the control box cover and access CB.

4) Check the S1 dip switch settings, see "II.C.4.a) Default Dip Switch Settings" to assure that they are in the correct positions. For proper operation of IS, conrm that S1 dip switch 7 is in the "ON" position.

WARNING

1. Risk of electric shock. Use extreme caution and exercise safe electrical practices.

. Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.

Page 59

5) Turn on the power supply, then move the power switch to the "ON" position. Make sure the control switch is in the "ICE" position. CB "POWER OK" LED and IS green LED turn on. Diagnosis "POWER OK" LED: Check that CB "POWER OK" LED is on. If not, check for proper supply voltage (115VAC) input to the control transformer. If 115VAC is not present, check the power switch and breaker. Next, check that the circuit protect relay is de-energized (closed between terminals #1 and #5). If the circuit protect relay is energized (08/30VAC), conrm proper power supply. The circuit protect relay helps protect 115VAC components from exposure to 08/30VAC. Next, check for proper outpout voltage (4VAC) from the control transformer. If "POWER OK" LED is off, check 4VAC at CB K8 connector pin #1 white/red (W/R) to pin # light blue (LBU). If 4VAC is not present, replace the control transformer. If 4VAC is present and "POWER OK" LED is off, CB is bad and must be replaced. Diagnosis IS: If "POWER OK" LED is on and IS green LED is off, check 0VDC at CB K6 connector brown (BR) wire to dark blue (DBU) wire. If 0VDC is not present, conrm dip switch 7 is in the "ON" position. If dip switch 7 is in the "ON" position and 0VDC is not present, CB is bad and must be replaced. If IS yellow LED is on or ashing, move ice away from IS lens. If no ice is present, clean the lens with a warm, clean damp cloth. If cleaning the lens does not work, replace IS. Diagnosis MBC: Conrm S1 dip switch 7 is in the "OFF" position. Check that the actuator paddle is properly positioned. Check for continuity across MBC proximity switch. When MBC proximity switch is closed 5VDC is present at CB K8 connector pin #3 or #4 gray (GY) to CB white K5 connector pin closest to red K4 connector (5VDC gnd). See Fig. 6. If 5VDC is not present, the control board is bad and must be replaced.

CB monitors the following switches with 5VDC: High-Pressure Switch, Gear Motor Protect Relay (relay terminals 3 & 5), and Mechanical Bin Control. When 5VDC is present across any of these switches, the switch is open.

6) Fill Cycle – "WTRIN" LED is on. WV energizes. The 90-second low water safety timer begins. LF/S closes. Nothing occurs at this time. The reservoir continues to ll until UF/S closes, terminating the 90-second low water safety timer, starting the 30-minute freeze timer, and de-energizing WV. Diagnosis: Check that "WTRIN" LED turns on. If not, make sure IS yellow LED is off. If not, move ice away from IS. If IS yellow LED does not turn off, clean the lens with a warm, clean damp cloth. If cleaning the lens does not work, replace IS. When "WTRIN" LED turns on, check that WV lls the reservoir. If not, check 4VAC to WV from CB K connector pin #8 white/brown (W/ BR) wire to a light blue (LBU) neutral wire. Check for continuity through WV solenoid. If open, replace WV. Check for water supply line shut-off valve closed, clogged water lters, and clogged WV screen. Check that DV is not leaking by. Check that WV shuts off when UF/S closes. If not, check UF/S, LF/S, CB, and WV. See "IV.E.1. Float Switch Check." Note: Low Water Safety–If UF/S remains open 90 seconds after WV energizes, a

1-beep alarm sounds. This alarm resets automatically once UF/S closes.

Page 60

7) Ice Purge Cycle – "GM" LED is on. 30-second GM delay timer and 30-minute freeze timer start. WV de-energizes and "WTRIN" LED turns off. Once the 30-second GM delay timer terminates, the 5-minute ice purge timer starts. GMR (X on CB), GM, GMPR, FM/FMR, and EHH (-C model only) energize. Diagnosis: If "GM" LED is off, check that WV de-energizes and UF/S closes. If "GM" LED is on and GM is off, conrm 115VAC at CB K1 connector pin #3 black (BK) to white (W) neutral. Check for 115VAC at CB K1 connector pin # brown (BR) to a white (W) neutral. If no voltage is present, CB is bad and must be replaced. If 115VAC is present, check GM fuse, thermal protector, and GM windings. If FM/FMR is on but GM is off, check GM capacitor, GM windings, and GM coupling between auger and GM. If FM/FMR does not start, check FM/FMR capacitor, FM/FMR windings, and FM/FMR bearings.

8) Freeze Cycle – "COMP" LED is on. "GM" LED remains on. Comp, LLV (MLH model), and SLV (MLH model) energize. GMR (X on CB), GM, GMPR, and FM/FMR continue. Ice production begins 4 to 6 minutes after Comp, LLV (MLH model), and SLV (MLH model) energize depending on ambient and water conditions. Diagnosis: Check that "COMP" LED is on and that Comp, or LLV (MLH model) and SLV (MLH model), energize. If "COMP" LED is off, check DC voltage across GMPR terminals 3 and 5 white/orange (W/O) wires. If 5VDC is present, GMPR contacts are open. Check GMPR solenoid voltage and solenoid continuity. Replace GMPR if necessary. If "COMP" LED remains off, CB is bad and must be replaced. If "COMP" LED is on and Comp is off, check for 115VAC at CB X1 Comp relay, Comp, LLV (MLH model), and SLV (MLH model). Check Comp internal overload (motor protector), start relay, and capacitors.

9) Rell Cycle/Low Water Safety Cycle – As ice is produced, the water level in the reservoir drops. UF/S opens. Nothing occurs at this time. When LF/S opens, WV energizes, 90-second low water safety timer (ll timer) starts. Comp, GMR, GM, GMPR, and FM/FMR continue. When UF/S closes, WV de-energizes, 90-second low water safety timer (ll timer) terminates and 30-minute freeze timer resets. If UF/S remains open 90 seconds after WV energizes (ll timer exceeded), a 90-second shutdown cycle starts. Comp de-energizes and CB signals a 1-beep alarm every 5 seconds. 90-second purge timer starts. GMR, GM, GMPR, and FM/FMR continue to clear ice from the evaporator. 90-second purge timer terminates, GMR, GM, GMPR, and FM/FMR de-energize. WV and 1-beep alarm continue until UF/S closes. Diagnosis – Check that "WTRIN" LED is on. If not, check LF/S. See "IV.E. Float Switch Check and Cleaning." If LF/S is open and "WTRIN" LED is off, CB is bad and must be replaced. If "WTRIN" LED is on, check that the reservoir lls. If not, check the water supply line, clogged water lters, WV solenoid, clogged WV screen. If WV is energized and rell exceeds 90-second low water safety timer (ll timer), check DV leaking by, UF/S open. See "IV.E. Float Switch Check and Cleaning." Note: Each time UF/S closes, 30-minute freeze timer starts. The 30-minute freeze timer

resets when UF/S closes again. If UF/S does not close again within 30 minutes, CB shuts down the unit and sounds a 5-beep alarm every 5 seconds. See "II. C.3.d) Freeze Timer (5-beep alarm)."

Page 61

10) Shutdown – See "IV.D. Bin Control Check."

Legend: CB–control board; Comp–compressor; DV–drain valve; EHH–extruding

head heater (-C model only); 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 only); valve (MLH model only); UF/S–upper oat switch; WV–inlet water valve

MBC–mechanical bin control; SLV–suction line

C. Control Board Check

Before replacing a control board that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis.

1) Check the S1 dip switch settings to assure that they are in the factory default position. S1 dip switch 7 is determined by bin control application:

Bin Control Application: Infrared Sensor Bin Control: S1 dip switch 7 in the "OFF" position. Mechanical Bin Control: S1 dip switch 7 in the "ON" position. For factory default settings, see "II.C.4.a) Default Dip Switch Settings."

) Move the power switch to the "ON" position and move the control switch to the "ICE"

position. The "POWER OK" LED turns on. Diagnosis "POWER OK" LED: Check that the "POWER OK" LED is on. If not, check for proper supply voltage (115VAC) input to the control transformer (power switch, breaker, fuse, and circuit protect relay). Next, check for proper low-voltage (4VAC) output from the control transformer and that the 1A fuse is good. Check for 4VAC from K8 connector pin #1 white/red (W/R) to K8 connector pin # light blue (LBU). If 4VAC is present and the "POWER OK" LED is off, the control board is bad and must be replaced.

3) "WTRIN" LED is on: When the lower or upper oat switch is open, the inlet water valve energizes and water lls the reservoir. Diagnosis: If "WTRIN" LED is off, upper oat switch is closed (reservoir full), "GM" LED is on, and the gear motor energizes, skip to step 8. If "WTRIN" and "GM" LED are off, conrm that the control switch is in the "ICE" position (open). Check that the yellow LED on the infrared sensor is not steady or ashing (see step 4 below). Next, check the continuity of the lower and upper oat switches (open or closed). For further details, see 5.f. below. If the lower or upper oat switch is open and the "WTRIN" LED is off, the control board is bad and must be replaced. If the "WTRIN" LED is on and the lower or upper oat switch is open, water should be lling the reservoir. If not, skip to step 6.

Page 62

4) Infrared Sensor (K6 connector): Check that the infrared sensor green LED is on. If not, check for 0VDC from the black K6 connector dark blue wire (DBU) to the K6 connector brown (BR) wire. See Fig. 4. If 0VDC is not present, the control board is bad and must be replaced. Next, conrm that the yellow LED is not ashing or steady. If IS yellow LED is on or ashing, move ice away from IS lens. If no ice is present, clean the lens with a warm, clean damp cloth. If cleaning the lens does not work, replace IS.

Infrared Sensor (0VDC) Closed 0VDC DBU to BR 0VDC DBU to W 0VDC W to BR

Infrared Sensor (0VDC) Open (yellow LED ashing or steady) 0VDC DBU to BR 0VDC DBU to W 0VDC W to BR

Dark Blue (DBU)

Brown (BR)

White (W)

Fig. 4

Red Positive Test Lead

Black Negative Test Lead

• K6 Connector

Infrared Sensor

0VDC

Multimeter

5) 5VDC control board switch output checks: Control Switch, High Pressure Switch, Gear Motor Protect Relay (terminals 3 & 5), Mechanical Bin Control Proximity Switch, and Float Switch. When checking 5VDC control voltage, always place the red positive test lead from the multimeter to the white K5 connector pin closest to the red K4 connector. See Fig. 5. Then place the black negative test lead from the multimeter to the corresponding pin to complete the 5VDC check. If the icemaker is in alarm (beeping), see "II.C..g) LED Lights and Alarm Safeties Chart."

Red positive test lead to white K5 connector pin closest to

red K4 connecotor

Red Positive Test Lead

Fig. 5

5VDC

Multimeter

Black Negative Test Lead

Control Board K9 Connector

6

Control Switch white/black (W/BK)

High-Pressure Switch yellow (Y) wires

Gear Motor Protect Relay (terminals #3 and #5)

white/orange (W/O)

Page 63

a. Control Switch (K9 connector pins #1 and # white/black (W/BK) wires): 5VDC is

present from the white K5 connector pin closest to red K4 connector to the K9 connector pin #1 white/black (W/BK) wire at all times. If 5VDC is not present, the control board is bad and must be replaced. When the control switch is in the "ICE" position, the control switch contacts are open. 0VDC is present from the white K5 connector pin closest to red K4 connector to the K9 connector pin # white/black (W/BK) wire. When in the "ICE" position, 5VDC is present from the K9 connector pin #1 white/black (W/BK) wire to pin # white/black (W/BK) wire. When the control switch is in the "DRAIN" position, the control switch contacts are closed. 5VDC is present from the white K5 connector pin closest to red K4 connector to the K9 connector pins #1 or # white/black (W/BK) wires. If 5VDC is not present the control board is bad and must be replaced. 0VDC is present from the K9 connector pin #1 white/black (W/BK) wire to pin # white/black (W/BK) wire.

b. High Pressure Switch (K9 connector pins #3 and #4 yellow (Y) wires): When the

high pressure switch is closed, 5VDC is present from the white K5 connector pin closest to red K4 connector to the K9 connector pins #3 and #4 yellow (Y) wires. If 5VDC is not present, the control board is bad and must be replaced. If 5VDC is present to K9 connector pin #3 yellow (Y) wire and not to K9 connector pin #4 yellow (Y) wire, the high pressure switch is open and the control board sounds a 3-beep alarm. Check continuity across the high pressure switch (K9 connector pins #3 and #4 yellow (Y) wires). When the high-pressure switch is closed, 0VDC is present from the K9 connector pin #3 yellow (Y) wire to K9 connector pin #4 yellow (Y) wire. When the high-pressure switch is open, 5VDC is present from the K9 connector pin #3 yellow (Y) wire to K9 connector pin #4 yellow (Y) wire. If the high pressure switch is open and the control board is not in alarm, the control board is bad and must be replaced.

c. Gear Motor Protect Relay (K9 connector pins #5 and #6 white/orange (WO) wires):

When the gear motor protect relay contacts terminals 3 and 4 are open (gear motor protect relay de-energized), 5VDC is present from the white K5 connector pin closest to red K4 connector to the K9 connector pin #5 white/orange (W/O) wire. If 5VDC is not present, the control board is bad and must be replaced. When the gear motor protect relay contacts terminals 3 and 4 are closed (gear motor protect relay energized), 5VDC is present from the white K5 connector pin closest to red K4 connector to the K9 connector pins #5 and #6 white/orange (W/O) wires. Also check from the K9 connector pin #5 white/orange (W/O) wire to K9 connector pin #6 white/orange (W/O) wire. If 0VDC is present, the gear motor protect relay contacts (terminals 3 & 5) are closed. If 5VDC is present, the gear motor protect relay contacts (terminals 3 & 5) are open and the control board may be in an 8-beep alarm. See "II.C.3.g) Gear Motor (8-beep alarm)."

d. Mechanical Bin Control (K8 connector pins #3 and #4 gray (GY) wires): When the

mechanical bin control proximity switch is closed (calling for ice), 5VDC is present from the white K5 connector pin closest to red K4 connector to the K8 connector pin #3 and #4 gray (GY) wires. If 5VDC is not present, the control board is bad and must be replaced. If 5VDC is present to pin #3 gray (GY) wire and not to pin #4 gray (GY) wire, the mechanical bin control proximity switch is open. See "IV.D.. Mechanical Bin Control Check."

Page 64

e. Float Switch (K8 connector pins #5 black (BK) wire, #6 red (R) wire (upper), and

#7 dark blue (DBU) wire (lower)): 5VDC is present from the white K5 connector pin closest to red K4 connector to the K8 connector pin #5 (black (BK) wire). If 5VDC is not present, the control board is bad and must be replaced. For further oat switch diagnostics, see "IV.E. Float Switch Check and Cleaning."

6) "WTRIN" LED is on, and the inlet water valve is off: Check that the water supply is on and that no water restrictions exist. Next, check for 4VAC from the K connector pin #7 white/red (W/R) wire to a light blue (LBU) wire. If 4VAC is present, check for 4VAC from the K connector pin #8 white/brown wire to a light blue (LBU) wire. If 4VAC is not present, the control board is bad and must be replaced. If 4VAC is present, check for 4VAC directly across the inlet water valve solenoid. If 4VAC is present, turn off the power supply and check continuity across the inlet water valve solenoid. If open, replace the inlet water valve.

7) "GM" LED is on and the gear motor and condenser fan are off: Check for 115VAC from the K1 connector pin # brown (BR) wire to a white (W) neutral wire. If 115VAC is not present, see "IV.B. Diagnostic Procedure" step 5. If 115VAC is present, check for 115VAC from the control board K1 connector pin #3 black (BK) wire to a white (W) neutral wire. If 115VAC is not present, the control board is bad and must be replaced.

8) "GM" and "COMP" LED are on and the compressor is off: (Note: To bypass the Ice Purge Cycle, press the "SERVICE" button after the "GM" LED turns on). Check for 115VAC from the control board X1 relay brown (BR) wire to a white neutral wire. If 115VAC is not present, see "IV.B. Diagnostic Procedure" step 5. If 115VAC is present, check X1 relay red (R) wire to a white neutral wire. If 115VAC is not present, the control board is bad and must be replaced.

Page 65

• K1 Connector

(115VAC)

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

• K2 Connector

(24VAC)

Drain Valve #10 (white/blue)

Transformer Input #9 (white/red)

Inlet Water Valve #8 (white/brown)

Transformer Input #7 (white/red)

Control Switch #1 to # (white/black) "ICE"-Open-5VDC "DRAIN"-Closed-0VDC

High Pressure Switch #3 to #4 (yellow) Open-5VDC Closed-0VDC

Gear Motor Protect Relay Circuit #5 to #6 (white/orange) Relay De-Energized-Open-5VDC Relay Energized-Closed-0VDC

• K9 Connector

• "SERVICE" Button

(Ice Purge Cycle Bypass)

• K8 Connector

(24VAC and 5VDC)

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

Transformer 4VAC Neutral # (light blue)

Mechanical Bin Control #3 to #4 (gray) Open-5VDC Closed-0VDC

Float Switch #5 (black)

Upper Float Switch #6 (red) Open-5VDC to #5 black Closed-0VDC to #5 black Lower Float Switch #7 (dark blue) Open-5VDC to #5 black Closed-0VDC to #5 black

• K7 Connector-open

5VDC common terminals

Fig. 6

Brown (BR)

White (W)

Dark Blue (DBU)

• "POWER OK" LED

• S1 Dip Switch

• K6 Connector (20VDC)

Infrared Sensor

Closed (yellow LED off) 0VDC DBU to BR 0VDC DBU to W 0VDC W to BR

Open (yellow LED ashing or steady) 0VDC DBU to BR 0VDC DBU to W 0VDC W to BR

Page 66

D. Bin Control Check

1. Infrared Sensor Check

IMPORTANT

Make sure S1 dip switch 7 is in the "ON" position. This allows the control board to monitor the infrared sensor along with the mechanical bin control.

1) Turn off the power supply.

) Remove the front panel, top panel, and control box cover.

3) Conrm that S1 dip switch 1, , & 3 are in the proper position for your application. See "II.C.4.b) Infrared Sensor Shutdown Delay (S1 dip switch 1, , & 3)."

4) Conrm that the infrared sensor is connected to the K6 connector on the control board. Wipe down the infrared sensor lens with a clean, warm, damp cloth.

5) Move the control switch to the "ICE" position, then move the power switch to the "ON" position.

6) Turn on the power supply to start the automatic icemaking process. Check that the infrared sensor green LED is on. This green LED conrms 0VDC power from the K6 connector on the control board to the infrared sensor and remains on constantly. Diagnosis: If the green LED is not on, check DC voltage at K6 connector dark blue (DBU) to brown (BR). If 0VDC is not present the control board is bad and must be replaced. If 0VDC is present and the green LED is off, the infrared sensor is bad and must be replaced.

7) Make sure the "GM" LED on the control board is on. There is a delay of at least 30 seconds before the "GM" LED turns on after power-up. After the "GM" LED turns on, press the "SERVICE" button on the control board to bypass the 5-minute ice purge cycle. See "II.C.1. Control Board Layout." WARNING! Risk of electric shock. Care should be taken not to touch live terminals. The "COMP" LED turns on.

8) "GM" and "COMP" LEDs are on. Use an object to cover the infrared sensor lens at the bottom of the icemaker. If the bottom of the icemaker is not accessible in your application, remove the thumbscrew securing the infrared sensor housing, remove the housing from the base, then cover the infrared sensor lens. See Fig. 7. The yellow LED on the infrared sensor 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), the infrared sensor shutdown delay timer starts . See "Infrared Sensor Shutdown Delay (S1 dip switch 1, , and 3)." The compressor should de-energize immediately after the shutdown delay timer expires. Five minutes later, the gear motor and fan motor should de-energize. Diagnosis: If the yellow LED is not on after covering the lens, the infrared sensor is bad and must be replaced. If the unit remains on after the infrared sensor shutdown delay timer expires and the 5-minute ice purge timer expires, the control board is bad and must be replaced. If the infrared sensor fails to shut down the icemaker and the level of ice activates the mechanical bin control, the icemaker shuts down within 10 seconds of the mechanical bin control opening and a 9-beep alarm sounds. To reset, turn the power off, and then on again.

Page 67

9) Remove the object covering the infrared sensor. If you removed the infrared sensor housing from the base, replace it in its correct position, and secure it with the thumbscrew.

10) Move the power switch to the "OFF" position. Turn off the power supply, then proceed to "IV.D.. Mechanical Bin Control Check."

Infrared Sensor LED

Infrared Sensor

Thumbscrew

Infrared Sensor LED

Infrared Sensor Housing

Fig. 7

Lens

2. Mechanical Bin Control Check

When the actuator paddle is not engaged the mechanical bin control is closed and the icemaker produces ice. a) Backup Bin Control: S1 dip switch 7 placed in the "ON" position, the mechanical bin control is used as a backup bin control safety. When ice lls the chute and engages the actuator paddle, the mechanical bin control opens and the control board shuts down the icemaker within 10 seconds and sounds a 9-beep alarm. b) Stand-Alone Bin Control: S1 dip switch 7 placed in the "OFF" position, the mechanical bin control is used as a stand-alone bin control. The stand-alone application should only be used in Hoshizaki standard ice storage bin applications. When ice lls the chute and engages the actuator paddle, the mechanical bin control opens and the control board shuts down the icemaker within 10 seconds. WARNING! Do not place S1 dip switch 7 in the "OFF" position on dispenser unit applications. See "II.C.4.a) Default Dip Switch Settings."

1) Make sure the power supply is off.

) Remove the strap connecting the spout to the chute assembly. See Fig. 8. Pull up the

chute assembly slightly so that you can access the actuator paddle located in the top of the chute.

3) Move the power switch to the "ON" position.

4) Turn on the power supply to start the automatic icemaking process.

Strap

Spout

Strap

Proximity Switch

Actuator Paddle

Chute Assembly

Fig. 8

Page 68

5) Make sure the "GM" LED is on. There is a delay of at least 30 seconds before the "GM" LED turns on after power-up. After the "GM" LED turns on, press the "SERVICE" button on the control board to bypass the 5-minute compressor delay. WARNING! Risk of electric shock. Care should be taken not to touch live terminals. The "COMP" LED turns on.

6) Press the actuator paddle located in the top of the chute. S1 dip switch 7 in the "ON" position: The compressor and gear motor should de-energize within 10 seconds and the control board should sound a 9-beep alarm. S1 dip switch 7 in the "OFF" position: The compressor and gear motor should de-energize within 10 seconds. Diagnosis: If the mechanical bin control fails to open or the icemaker fails to shut down, check that the actuator paddle is moving freely. Conrm that the actuator paddle is engaged. Check for continuity across the mechanical bin control wires. If the mechanical bin control is found open and the icemaker continues to run, the control board is bad and must be replaced. If the mechanical bin control is found closed with the actuator paddle engaged, the mechanical bin control proximity switch is bad and must be replaced.

7) Move the power switch to the "OFF" position and turn off the power supply.

8) Replace the chute assembly and strap in their correct positions.

9) Move the power switch to the "ON" position.

10) Replace the control box cover, top panel, and front panel in their correct positions.

11) Turn on the power supply to start the automatic icemaking process.

Page 69

E. Float Switch Check and Cleaning

1. Float Switch Check

1) Remove the front panel and move the power switch to the "OFF" position. Move the control switch to the "DRAIN" position.

) Move the power switch to the "ON" position.

3) Allow the water to drain from the reservoir, then move the power switch to the "OFF" position and the control switch to the "ICE" position.

4) Remove the molex plug from the control box and check continuity across the oat switch wires. Black (BK) to red (R) for the upper oat and black (BK) to dark blue (DBU) for the lower oat. See Fig. 9. With the water reservoir empty, the oat switches are open. If open, continue to step 5. If closed, follow the steps in "IV.E.. Float Switch Cleaning." After cleaning the oat switches, check them again. Replace if necessary.

5) Replace the molex plug on the control box.

6) Move the power switch to the "ON" position and let the water reservoir ll.

7) Once the reservoir is full and the gear motor starts, move the power switch to the "OFF" position.

8) Remove the molex plug from the control box and check continuity across the oat switch wires. Black (BK) to red (R) for the upper oat and black (BK) to blue (DBU) for the lower oat. They should be closed. Clean or replace if necessary.

2. Float Switch Cleaning

Depending on local water conditions, scale may build up on the oat switch. Scale on the switch can cause the oats to stick. In this case, the oat switch should be cleaned and checked.

1) Turn off the power supply.

) Remove the oat switch assembly from the reservoir cover. See Fig. 10.

3) Wipe down the oat switch assembly with a mixture of 1 part recommended cleaner Hoshizaki "Scale Away" or "LIME-A-WAY" (Economics Laboratory, Inc.) and 5 parts warm water. Rinse the assembly thoroughly with clean water.

4) While not necessary, the oats can be removed from the shaft during cleaning. If you remove them, note that the blue oat is on top. The oats must be installed with the magnets inside them towards the top of the switch. Installing the oats upside down will affect the timing of the oat switch operation. See Fig. 9.

5) Rinse the oat switch assembly thoroughly with clean water and replace in its original position.

Page 70

Red (R) (upper ﬂoat switch)

Black (BK) (common)

Dark Blue (DBU) (lower ﬂoat switch)

Magnet (towards top)

Upper Float (blue)

Magnet (towards top)

Lower Float (white)

Float Switch Assembly

Spring Retainer Clip

Plastic Retainer Clip

Fig. 9

Reservoir Cover

Reservoir

Fig. 10

Page 71

F. Diagnostic Charts

1. No Ice Production

Problem Possible Cause Remedy

[1] The icemaker will not

start.

a) Power Supply 1. Off, blown fuse, or

tripped breaker.

Loose connection. . Tighten.

.

3. Bad contacts. 3. Check for continuity and

4. Not within specications.

b) Water Supply 1. Water supply off or

pressure too low.

c) Power Switch

(Control Box)

d) Circuit Protect Relay 1. Power supply not

e) Transformer 1. Coil winding opened. 1. Replace.

f) Fuse (Control Box) 1. Blown. 1. Check for short circuit and

g) Infrared Sensor 1. No power or defective. 1. See "IV.D. Bin Control

h) Mechanical Bin

Control (Backup Bin Control Safety)

i) High Pressure Switch 1. Bad Contacts. 1. Check for continuity and

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

Bad contacts. . Check for continuity and

.

within specications.

Bad Contacts. . Check for continuity and

.

1. Tripped with bin lled with ice. (9-beep alarm)

Mechanical bin control

.

stuck open.

3. Actuator paddle does not move freely.

Dirty air lter or

.

condenser.

3. Ambient or condenser water temperature too warm.

4. Refrigerant overcharged.

5. Fan not operating (except water-cooled model).

6. Refrigerant line or component restricted.

1. Turn on, replace, or reset.

replace.

4. Refer to nameplate and correct.

1. Check and get recommended pressure.

replace.

1. Refer to nameplate and correct or re-wire.

replace.

Check."

1. Remove ice.

. See "IV.D. Bin Control

Check."

3. Clean shaft and its corresponding holes or replace damaged components.

replace.

. Clean.

3. Reduce temperature.

4. Recharge.

5. See chart "3.[.]a) Fan Motor"

6. Remove the restriction or component and replace the drier.

Page 72

Problem Possible Cause Remedy

[1] The icemaker will not

start (continued).

i) High Pressure Switch

(continued)

7. Condenser water pressure too low or off (water-cooled model).

7. Check and get recommended pressure.

Fill cycle will not

[]

terminate.

Ice purge cycle will

[3]

not start.

Freeze cycle will not

[4]

start (compressor).

8. Water regulating valve set too high (water-cooled model).

j) Control Switch 1. "DRAIN" position. 1. Move to "ICE" position.

Bad contacts. . Check for continuity and

.

k) Inlet Water Valve 1. Coil winding opened. 1. Replace.

l) Control Board 1. Defective. 1. See "IV.B. Diagnostic

a) Float Switch 1. Bad contacts. 1. Check for continuity and

Float does not move

.

freely.

b) Drain Water Valve 1. Valve seat clogged

and water leaking.

c) Hoses 1. Disconnected. 1. Connect.

d) Control Board 1. Defective. 1. See "IV.B. Diagnostic

a) Control Board 1. Defective. 1. See "IV.B. Diagnostic

b) Gear Motor Fuse 1. Blown. 1. Check gear motor

c) Gear Motor Thermal

Protector

d) Gear Motor Protect

Relay

e) Gear Motor 1. Open windings. 1. Replace.

a) Control Board 1. Defective. 1. See "IV.B. Diagnostic

b) Starter (start relay) 1. Bad contacts. 1. Check for continuity and

c) Start Capacitor or Run

Capacitor

1. Open. 1.Check gear motor bearings,

1. Open windings. 1. Replace.

Open or stuck

.

contacts.

Auger coupling broke. . Replace.

.

3. Locked bearings. 3. Replace.

Coil winding opened. . Replace.

.

3. Loose connections. 3. Tighten.

1. Defective, weak. 1.Replace.

8. Adjust it lower.

replace.

Procedure."

replace.

. Clean or replace.

1. Clean or replace.

Procedure."

amperage, bearing wear (see "V.D.1. Upper Bearing Wear Check"), supply voltage.

voltage supply.

. Replace.

Procedure."

replace.

7

Page 73

Problem Possible Cause Remedy

Freeze cycle will not

[4]

start (compressor) (continued).

[5] Freeze cycle

starts, but no ice is produced.

d) Compressor 1. Wiring to compressor. 1. Check for loose or open

connection, repair or replace.

.

Loose connections. . Tighten.

3. Motor winding opened or grounded.

4. Compressor locked and motor protector tripped.

e) Power Supply 1. Not within

specications.

a) Refrigerant Line 1. Gas leaks. 1. Check for leaks with a leak

Refrigerant line or

.

component restricted.

b) Expansion Valve

(TXV) (not adjustable)

c) Compressor 1. Defective. 1.See ".[1]g) Compressor".

d) Headmaster (C.P.R.)

(remote air-cooled model)

e) Water Supply Line

(water-cooled model)

f) Water Regulating

Valve (water-cooled model)

1. Defective. 1. Replace.

1. Not operating properly and liquid line temperature too warm.

1. Condenser water pressure too low or off and high pressure control opens and closes frequently.

1. Set too high. 1. Adjust or replace. See

3. Replace.

4. Replace.

1. Refer to nameplate and correct.

detector. Repair leaks. Replace drier and charge with refrigerant. See "V.A. Service for Refrigerant Lines."

. Remove the restriction or

component and replace the drier.

1. Replace.

1. Check and get recommended pressure.

"V.H. Adjustment of Water Regulating Valve."

Page 74

2. Low Ice Production

Problem Possible Cause Remedy

[1] Low ice production. a) Evaporator 1. Dirty. 1. Clean. See "VI.A.

Cleaning and Sanitizing Instructions."

b)Bin Control 1. Erratic, sticking,

defective.

c) Losing Water 1. Drain valve leaking. 1. Clean or replace.

Mechanical seal

.

leaking.

3. O-ring leaking. 3. Replace.

d)Expansion Valve (TXV)

(not adjustable)

e)Refrigerant Line 1. Gas leaks. 1. Check for leaks with a leak

f) High-Side Pressure

Too High

g)Compressor 1. Inefcient compressor. 1. Replace compressor.

1. Low-side pressure too low.

Low-side pressure too

.

high.

Refrigerant lines or

.

components restricted

3. Overcharged. 3. Recharge.

1. Dirty air lter or condenser.

Ambient or condenser

.

water temperature too warm.

3. Fan motor slow rpm. 3. See "3.[]a) Fan Motor".

4. Fan motor capacitor. 4. Check and Replace.

5. Condenser water pressure too low or off (water-cooled model).

6. Water regulating valve restricted (water-cooled model).

Faulty thermal

.

protector (overload).

3. Faulty capacitor/ starter.

1. See "IV.D. Bin Control Check."

. Replace.

1. Replace.

. See if expansion valve

bulb is mounted properly, and replace the valve if necessary.

detector. Repair leaks. Replace drier and charge with refrigerant. See "V.A. Service for Refrigerant Lines."

. Remove the restriction or

component and replace the drier.

1. Clean.

. Reduce temperature.

5. Check and get recommended pressure.

6. Clean.

. Replace compressor.

3. Replace components.

Page 75

3. Other

Problem Possible Cause Remedy

[1] Icemaker will not stop

when bin is lled with ice.

Abnormal noise a)Fan Motor (except

[]

[3] Overow from

reservoir (water does not stop).

[4] Gear motor protector

operates frequently or fuse blows frequently.

a)Bin Control 1. Erratic or defective. 1. See "IV.D. Bin Control

Check."

1. Bearing worn out. 1. Replace.

water-cooled model)

b)Compressor 1.Bearings worn out, or

c) Refrigerant Lines 1. Rub or touch lines or

d)Auger 1. Bearings or auger

e)Gear Motor 1. Bearing or gear worn

f) Evaporator 1.Scale on inside wall

a)Water Supply 1. Water pressure too

b)Inlet Water Valve 1. Diaphragm does not

c) Float Switch 1. Bad contacts. 1. Check for continuity and

a)Power Supply 1. Not within

b)Evaporator Assembly 1.Gear motor bearings

c) Bin Control 1. Defective. 1. See "IV.D. Bin Control

d)Control Board 1. Erratic operation of

. Fan blade deformed. . Replace fan blade.

3. Fan blade does not move freely.

cylinder valve broken.

Mounting pad out of

.

position.

other surfaces.

worn out.

out / damaged.

of evaporator freezing cylinder.

Low refrigerant

.

pressures.

3. Expansion valve bad. 3.Replace.

4. Evaporator bad. 4. Replace.

high.

close.

specications.

or auger bearings worn out.

Actuator does not

.

move freely.

gear motor relay.

3. Replace.

1. Replace.

. Reinstall.

1. Reposition.

1. Replace bearings or auger. See "V.D.1. Upper Bearing Wear Check."

1. Replace.

1. Use "SCALE AWAY" solution to clean periodically. If the water is found hard by testing, install a softener.

. Check charge, check for

possible leak, repair, re-charge.

1. Install a pressure reducing valve.

1. Clean or replace.

replace.

1. Refer to nameplate and correct.

1. Replace bearings or auger. See "V.D.1. Upper Bearing Wear Check."

Check."

. Clean shaft and its

corresponding holes or replace bin control.

1. See "IV.B. Diagnostic Procedure."

Page 76

V. Removal and Replacement of Components

WARNING

1. This unit should be diagnosed and repaired only by qualied service personnel to reduce the risk of death, electric shock, serious injury, or re.

. Move the power switch to the "OFF" position and turn off the power supply

before servicing. Lockout/Tagout to prevent the power from being turned back on inadvertently.

3. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the equipment is serviced. Make sure that none have fallen into the dispenser unit/storage bin.

4. Make sure all food zones in the icemaker and dispenser unit/storage are clean after the unit is serviced. For cleaning procedures, see "VI. Cleaning and Maintenance."

A. Service for Refrigerant Lines

WARNING

1. Repairs requiring the refrigeration circuit to be opened must be performed by properly trained and EPA-certied service personnel.

. Always recover the refrigerant and store it in an approved container. Do not

discharge the refrigerant into the atmosphere.

3. Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

CAUTION

1. Do not leave the system open for longer than 15 minutes when replacing or servicing parts. The Polyol Ester (POE) oils used in R-404A units can absorb moisture quickly. Therefore it is important to prevent moisture from entering the system when replacing or servicing parts.

. Always install a new drier every time the sealed refrigeration system is

opened.

3. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

4. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating. Do not allow the drier to exceed 50°F (11°C).

1. Refrigerant Recovery (except MLH model)

The icemaker unit is provided with refrigerant access valves. Using proper refrigerant practices, recover the refrigerant from the access valves and store it in an approved container. Do not discharge the refrigerant into the atmosphere.

Page 77

2. Brazing

WARNING

1. R-404A itself is not ammable at atmospheric pressure and temperatures up to 176°F (80°C).

. R-404A itself is not explosive or poisonous. However, when exposed to

high temperatures (open ames), R-404A can be decomposed to form hydrouoric acid and carbonyl uoride both of which are hazardous.

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

4. Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

1) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating. Do not allow the drier to exceed 50°F (11°C).

) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of

refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

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

1) Attach a vacuum pump to the system. Be sure to connect charging hoses to both high and low-side access valves.

IMPORTANT

The vacuum level and vacuum pump may be the same as those for current refrigerants. However, the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils.

) Turn on the vacuum pump. Never allow the oil in the vacuum pump to ow backwards.

3) Allow the vacuum pump to pull down to a 9.9" Hg vacuum. Evacuating period depends on pump capacity.

4) Close the low-side valve and high-side valve on the gauge manifold.

Page 78

5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled models, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used.

6) A liquid charge is recommended for charging an R-404A system. Invert the service cylinder and place it on scales. Open the high-side valve on the gauge manifold.

7) Allow the system to charge with liquid until the proper charge weight is met.

8) If necessary, add any remaining charge to the system through the low-side. Use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low-side access port with the unit running.

9) Close the gauge manifold valves and disconnect the gauge manifold hoses.

10) Cap the access valves to prevent a possible leak.

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

system)

a) Refrigerant Recovery

Using proper refrigerant practices, close the liquid and suction line service valves at the rack system. Then, follow the steps below to recover the refrigerant from the line set and icemaker and store it in an approved container. Do not discharge the refrigerant into the atmosphere.

1) Turn off the icemaker power supply.

) Close the liquid and suction line service valves at the rack system.

3) Connect gauge manifold hoses to the line set liquid and suction access valves.

4) Place magnets on top of the liquid and suction line solenoids.

5) Recover the refrigerant from the line set and icemaker. Note the charge amount removed. Do not discharge the refrigerant into the atmosphere.

b) Brazing

See "V.A.. Brazing."

c) Evacuation and Recharge (R-404A)

1) Attach a vacuum pump to the system. Be sure to connect charging hoses to both liquid and suction access valves.

IMPORTANT

) Turn on the vacuum pump. Never allow the oil in the vacuum pump to ow backwards.

3) Allow the vacuum pump to pull down to a 9.9" Hg vacuum. Evacuating period depends on pump capacity.

Page 79

4) Close the low-side valve and high-side valve on the gauge manifold.

5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used.

6) A liquid charge is recommended for charging an R-404A system. Invert the service cylinder and place it on scales. Open the high-side valve on the gauge manifold.

7) Allow the system to charge with liquid until a charge weight equal to the charge weight removed earlier in step "4.a)5)" is met.

8) Remove the magnets from the liquid and suction line valves.

9) Close the gauge manifold valves.

10) Open the rack system liquid and suction line service valves.

11) Turn on the power supply.

1) Allow the system to run, then conrm the EPR (evaporator pressure regulator) setting.

EPR Setting: 3 PSIG for evaporator temperature no less than 5°F (-15°C).

13) Disconnect the gauge manifold hoses.

14) Cap the access valves to prevent a possible leak.

B. Removal and Replacement of Compressor

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating. Do not allow the drier to exceed 50°F (11°C).

Note: When replacing a compressor with a defective winding, be sure to install the

new start capacitor and start relay supplied with the replacement compressor. Due to the ability of the POE oil in the compressor to absorb moisture quickly, the compressor must not be opened more than 15 minutes for replacement or service. Do not mix lubricants of different compressors even if both are charged with R-404A, except when they use the same lubricant.

1) Turn off the power supply.

) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the terminal cover on the compressor, and disconnect the compressor wiring. On remote air-cooled models, disconnect the crankcase heater.

5) Remove the drier and the discharge, suction, and process pipes.

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6) Remove the hold-down bolts, washers, and rubber grommets.

7) Remove the compressor. Unpack the new compressor package.

8) Attach the rubber grommets of the prior compressor to the new compressor.

9) Place the compressor in position and secure it using the bolts and washers.

10) Place the new drier in position.

11) Remove plugs from the suction, discharge, and process pipes.

1) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

13) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

14) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled models, see the rating label inside the icemaker.

15) Connect the terminals, and replace the terminal cover in its correct position. On remote air-cooled models, connect the crankcase heater.

16) Replace the panels in their correct positions.

17) Turn on the power supply.

C. Removal and Replacement of Expansion Valve

Moisture in the refrigeration circuit may exceed drier capacity and freeze up at the expansion valve.

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect the valve body and drier by using wet cloths to prevent the valve body and drier from overheating. Do not allow the valve body or drier to exceed 50°F (11°C).

1) Turn off the power supply.

) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the insulation and the expansion valve bulb on the suction line.

5) Remove the expansion valve cover and disconnect the expansion valve. Place the new expansion valve in position.

6) Remove the drier, then place the new drier in position.

7) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

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8) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

9) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled model, see the rating label inside the icemaker.

10) Attach the expansion valve bulb to the suction line in the same location as the previous bulb. The bulb should be between the 10 and  o'clock position on the tube. Be sure to secure the bulb with the clamp and holder and to insulate it.

11) Place the expansion valve cover in position.

1) Replace the panels in their correct positions.

13) Turn on the power supply.

D. Removal and Replacement of Evaporator Assembly Components

CAUTION

On aker models, make sure the cutter pin is in place after service. On cubelet models, make sure the extruding head heater is installed after service.

Extruding Head Heater (-C models only)

Cutter Pin (Flaker models only)

Auger

Allen Head Cap Screw

Spring Retainer

Mechanical Seal

O-Ring

Housing-Lower Bearing

Cutter, Bolt, and Washer

Extruding Head Upper Bearing

Evaporator

Allen Head Cap Screw with Washer

Hex Head Bolts

Spline Coupling

Barrier

Gear Motor

Fig. 11

Page 82

1. Upper Bearing Wear Check

To ensure that the bearing inside the extruding head does not exceed the wear tolerance of .0", follow the instructions below.

1) Turn off the power supply.

) Remove the panels.

3) Remove the strap connecting the spout to the chute assembly, then remove the spout.

4) Remove the bolt from the auger and lift off the cutter.

5) Replace the bolt in the auger. Grasp the bolt at the top of the auger and move the auger towards you and then try to insert a .0" round stock or pin gauge in between the back side of the auger shaft and the bearing surface. Check several locations around the auger shaft. If the gauge goes between the shaft and the bearing at any point or if the bearing is scratched or cracked, both the top bearing in the extruding head and the lower bearing in the housing should be replaced. Instructions for removing the extruding head and housing are located later in this procedure. Note: Replacing the bearing requires a bearing press adaptor. If one is not available,

replace the whole extruding head and housing.

.0" Round Stock or Pin Gauge

Auger

Extruding Head

Fig. 12

6) Remove the bolt. Replace the cutter and then the cutter bolt.

7) Replace the spout.

8) Replace the panels in their correct positions.

9) Turn on the power supply.

2. Removal and Replacement of Cutter

1) Turn off the power supply.

) Remove the panels.

3) Remove the strap connecting the spout to the chute assembly, then remove the spout.

4) Remove the bolt and lift off the cutter.

5) Install the new cutter and replace the bolt.

6) Replace the spout.

7) Replace the panels in their correct positions.

8) Turn on the power supply.

8

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3. Removal and Replacement of Extruding Head

1) Drain the water from the evaporator. a) Move the power switch to the "OFF" position. b) Move the control switch to the "DRAIN" position. c) Move the power switch to the "ON" position and allow the water to drain from the

evaporator.

d) Move the power switch to the "OFF" position, then turn off the power supply.

) Remove the panels.

3) Remove the strap connecting the spout to the chute assembly, then remove the spout.

4) Remove the bolt and lift off the cutter.

5) Remove the allen head cap screws and lift off the extruding head.

6) Place the new extruding head in place and tighten down the allen head cap screws.

7) Replace the cutter, cutter bolt, and spout.

8) Replace the panels in their correct positions.

9) Move the drain switch to the "ICE" position. Then, turn on the power supply.

4. Removal and Replacement of Auger

evaporator.

d) Move the power switch to the "OFF" position.

) Turn off the power supply.

3) Remove the panels.

4) Remove the strap connecting the spout to the chute assembly, then remove the spout.

5) Remove the allen head cap screws securing the extruding head. Using the cutter, lift

out the auger assembly.

6) Remove the cutter bolt, cutter pin (aker only), cutter, and extruding head from the

auger and place on the new auger. (On aker models, a new cutter pin is supplied with the new auger.)

7) Install the new auger.

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

9) Replace the panels in their correct positions.

10) Move the drain switch to the "ICE" position. Then, turn on the power supply.

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5. Removal and Replacement of Evaporator

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating. Do not allow the drier to exceed 50°F (11°C).

evaporator.

d) Move the power switch to the "OFF" position, then turn off the power supply.

) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the strap connecting the spout to the chute assembly, then remove the spout.

5) Disconnect the water hoses.

6) Remove the allen head cap screws securing the extruding head. Using the cutter, lift

out the auger assembly.

7) Remove the insulation and the expansion valve bulb on the suction line.

8) Disconnect the inlet and outlet tubing.

9) Remove the allen head cap screws securing the evaporator to the lower housing.

10) Lift off the evaporator.

11) Inspect the mechanical seal and O-ring prior to installing the new evaporator. The mechanical seal consists of two parts. One moves along with the auger, and the other is xed on the lower housing. If the contact surfaces of these two parts are worn, cracked, or scratched, the mechanical seal may cause water leaks and should be replaced. Instructions for removing the mechanical seal and lower housing are located later in this procedure.

1) Make sure the lower mechanical seal is in place, then place the evaporator in position.

Secure the evaporator to the lower housing using the allen head cap screws.

13) Remove the drier, then place the new drier in position.

14) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

15) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

Page 85

16) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled models, see the rating label inside the icemaker.

17) Replace the removed parts in the reverse order of which they were removed.

18) Replace the panels in their correct positions.

19) Move the drain switch to the "ICE" position. Then, turn on the power supply.

6. Removal and Replacement of Mechanical Seal and Lower Housing

6a. Mechanical Seal

evaporator.

d) Move the power switch to the "OFF" position.

) Turn off the power supply.

3) Remove the panels.

4) Remove the strap connecting the spout to the chute assembly, then remove the spout.

5) Remove the allen head cap screws securing the extruding head. Using the cutter, lift

out the auger assembly.

6) The mechanical seal consists of two parts. One moves along with the auger, and the

other is xed on the lower housing. If the contact surfaces of these two parts are worn, cracked, or scratched, the mechanical seal may cause water leaks and should be replaced.

7) Remove the allen head cap screws securing the evaporator to the lower bearing

housing.

8) Raise the evaporator up to access the lower housing.

9) Remove the O-ring and mechanical seal from the housing. If only replacing the

mechanical seal, proceed to step 1.

WARNING

To help prevent water leaks, be careful not to damage the surfaces of the O-ring or mechanical seal.

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6b. Lower Housing

10) Remove the bolts securing the housing to the gear motor and remove the housing from the gear motor. If inspection of the upper bearing inside the extruding head (see "V.D.1. Upper Bearing Wear Check") indicates that it is out of tolerance, replace both it and the bearing inside the lower housing. Note: Replacing the bearing requires a bearing press adaptor. If one is not available,

replace the whole extruding head and housing.

11) Mount the lower housing on the gear motor.

1) Install the O-ring and lower part of the mechanical seal on the lower housing.

13 ) Lower the evaporator down and secure it to the lower housing.

14) Install the auger assembly with the upper part of the mechanical seal attached.

15) Replace the removed parts in the reverse order of which they were removed.

16) Replace the panels in their correct positions.

17) Move the drain switch to the "ICE" position. Then, turn on the power supply.

7. Removal and Replacement of Gear Motor

evaporator.

d) Move the power switch to the "OFF" position.

) Turn off the power supply.

3) Remove the panels.

4) Remove the strap connecting the spout to the chute assembly, then remove the spout.

5) Remove the bolts securing the lower housing to the gear motor. Lift the evaporator up

slightly.

6) Remove the bolts securing the gear motor.

7) Disconnect the gear motor wiring, then remove the gear motor.

8) Remove the gear motor bracket and spline coupling from the old gear motor and place

on the new gear motor.

9) Install the new gear motor and re-connect the electrical wires.

10) Replace the removed parts in the reverse order of which they were removed.

11) Replace the panels in their correct positions.

1) Move the drain switch to the "ICE" position. Then, turn on the power supply.

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E. Removal and Replacement of Air-Cooled Condenser

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating. Do not allow the drier to exceed 50°F (11°C).

1) Turn off the power supply.

) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Disconnect the condenser inlet and outlet piping.

5) Remove the corner barrier from the condenser.

6) Remove the screws securing the condenser assembly, then remove the assembly.

7) Install the new condenser, then attach the corner barrier.

8) Remove the drier, then place the new drier in position.

9) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

10) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

11) Evacuate the system, and charge it with refrigerant. See the nameplate for the required refrigerant charge.

1) Replace the panels in their correct positions.

13) Turn on the power supply.

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F. Removal and Replacement of Water-Cooled Condenser

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect the drier by using a wet cloth to prevent the drier from overheating. Do not allow the drier to exceed 50°F (11°C).

1) Turn off the power supply.

) Remove the panels.

3) Close the condenser water supply line shut-off valve. If connected to a closed loop water supply, also close the condenser return outlet shut-off valve.

4) Open the condenser water supply line drain valve. If connected to a closed loop water supply, also open the condenser return outlet drain valve.

5) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve.

6) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out.

7) Recover the refrigerant and store it in an approved container.

8) Disconnect the condenser water inlet and outlet piping and the refrigeration inlet and outlet piping at the condenser.

9) Remove the old condenser and install the new condenser.

10) Remove the drier, then place the new drier in position.

11) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

1) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of

refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

13) Evacuate the system, and charge it with refrigerant. See the nameplate for the required refrigerant charge.

14) Close the drain valve(s). Open the condenser water supply line shut-off valve. If connected to a closed loop water supply, also open the condenser return outlet shut-off valve.

15) Check for water leaks.

16) Replace the panels in their correct positions.

17) Turn on the power supply.

Page 89

G. Removal and Replacement of Water Regulating Valve -

Water-Cooled Model

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect WRV and drier by using wet cloths to prevent the WRV and drier from overheating. Do not allow the WRV or drier to exceed 50°F (11°C).

1) Turn off the power supply.

) Remove the panels.

3) Close the condenser water supply line shut-off valve. If connected to a closed loop water supply, also close the condenser return outlet shut-off valve.

4) Open the condenser water supply line drain valve. If connected to a closed loop water supply, also open the condenser return outlet drain valve.

5) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve.

7) Recover the refrigerant and store it in an approved container.

8) Disconnect the capillary tube at the condenser outlet.

9) Disconnect the are-connections of the valve.

10) Remove the screws and the valve from the bracket.

11) Install the new valve.

1) Remove the drier, then place the new drier in position.

13) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

14) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

15) Evacuate the system, and charge it with refrigerant. See the nameplate for the required refrigerant charge.

16) Connect the are-connections.

17) Close the condenser water supply line drain valve. If connected to a closed loop water supply, also close the condenser return outlet drain valve.

Page 90

18) Open the condenser water supply line shut-off valve. If connected to a closed loop water supply, also open the condenser return outlet shut-off valve.

19) Check for water leaks.

0) Replace the panels in their correct positions.

1) Turn on the power supply.

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

The water regulating valve (also called "water regulator") is factory-adjusted. No adjustment is required under normal use. Adjust the water regulator, if necessary, using the following procedure.

1) Prepare a thermometer to check the condenser outlet temperature. Attach a pressure gauge to the high-side line of the system.

) Five minutes after a freeze cycle starts,

conrm that the thermometer reads 104°F to 115°F (40°C to 46°C). If it does not, rotate the adjustment screw by using a at blade screwdriver until the temperature is in the proper range. See Fig. 13. Next, check that the reference pressure is in the range indicated in the Head Pressure table in the Performance Data section. If it is not in the proper range, verify the refrigerant charge.

3) Check that the condenser drain temperature is stable.

Top View

Adjustment Screw

CCW – Higher CW – Lower

Fig. 13

I. Removal and Replacement of Fan Motor (air-cooled and remote

air-cooled models)

Note: When replacing a fan motor with defective winding, it is recommended that a new

capacitor be installed.

1) Turn off the power supply.

) Remove the panels.

3) Remove the junction box cover from the remote condenser unit (remote air-cooled model).

4) Disconnect the fan motor wires and the capacitor wires.

5) Remove the fan motor bracket (air-cooled model), fan motor, and capacitor.

6) Install the new fan motor onto the fan motor bracket (air-cooled model). Install the fan motor assembly and connect the fan motor wires. Make sure the wires are properly routed in the wire saddles and do not interfere with the fan blade. Install the capacitor and connect the capacitor wires.

7) Replace the panels in their correct positions.

8) Replace the junction box cover in its correct position (remote air-cooled model).

9) Turn on the power supply.

Page 91

J. Removal and Replacement of Headmaster (Condensing Pressure

Regulator - C.P.R.) - Remote Air-Cooled Model

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect the C.P.R. and drier by using wet cloths to prevent the C.P.R. and drier from overheating. Do not allow the C.P.R. or drier to exceed 50°F (11°C).

1) Turn off the power supply.

) Remove the panels from the remote condenser unit.

3) Recover the refrigerant and store it in an approved container.

4) Before heating, break off the stub on the dome to release the dome charge.

5) Disconnect the headmaster.

6) Place the new headmaster in position.

7) Remove the drier, then place the new drier in position.

8) Braze all ttings with nitrogen gas owing at a pressure of 3 to 4 PSIG.

9) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with pressurized air for leak testing.

10) Evacuate the system and charge it with refrigerant. See the rating label inside the icemaker, for the required refrigerant charge.

11) Replace the panels in their correct positions.

1) Turn on the power supply.

Page 92

K. Removal and Replacement of Liquid Line Valve or Suction Line Valve

- MLH Model (low side, parallel rack system)

CAUTION

1. Always replace the strainer when replacing the liquid line valve.

. Always install a new drier every time the sealed refrigeration system is

opened.

3. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

4. When brazing, protect the valve body and drier by using wet cloths to prevent the valve body and drier from overheating. Do not allow the valve body or drier to exceed 50°F (11°C).

1) Turn off the power supply.

) Remove the panels.

3) Isolate the icemaker from the rack system. See "V.A.4. Refrigerant Recovery, Evacuation, and Recharge - MLH Model (low side, parallel rack system)" or the rack system manufacturer's instructions.

4) Recover the refrigerant from the icemaker and store it in an approved container.

5) Remove the screw and the solenoid.

6) Disconnect the valve and strainer.

7) Place the new valve and strainer in position.

8) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

10) Evacuate and recharge the system. See "V.A.4. Refrigerant Recovery, Evacuation, and Recharge - MLH Model (low side, parallel rack system)" or the rack system manufacturer's instructions.

11) Cut the leads of the solenoid allowing enough lead length to reconnect using closed end connectors.

1) Connect the new solenoid leads.

13) Attach the solenoid to the valve body and secure it with the screw.

14) Replace the panels in their correct positions.

15) Turn on the power supply.

9

Page 93

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

MLH Model (low side, parallel rack system)

CAUTION

1. Always install a new drier every time the sealed refrigeration system is opened.

. Do not replace the drier until after all other repair or replacement has been

made. Install the new drier with the arrow on the drier in the direction of the refrigerant ow.

3. When brazing, protect the E.P.R. and drier by using wet cloths to prevent the E.P.R. and drier from overheating. Do not allow the E.P.R. or drier to exceed 50°F (11°C).

1) Turn off the power supply.

) Remove the panels.

3) Isolate the icemaker from the rack system. See "V.A.4. Refrigerant Recovery, Evacuation, and Recharge - MLH Model (low side, parallel rack system)" or the rack system manufacturer's instructions.

4) Recover the refrigerant and store it in an approved container.

5) Remove the E.P.R. valve.

6) Place the new E.P.R. valve in position.

7) Braze all ttings while purging with nitrogen gas owing at a pressure of 3 to 4 PSIG.

9) Evacuate and recharge the system. See "V.A.4. Refrigerant Recovery, Evacuation, and Recharge - MLH Model (low side, parallel rack system)" or the rack system manufacturer's instructions.

10) Replace the panels in their correct positions.

11) Turn on the power supply.

M. Removal and Replacement of Water Valves

1. Inlet Water Valve

1) Turn off the power supply.

) Remove the panels.

3) Close the water supply line shut-off valve

4) Open the water supply line drain valve.

5) Disconnect the terminals from the inlet water valve.

Page 94

6) Loosen the tting nut on the inlet water valve, and remove the inlet water valve. Do not lose the packing inside the tting nut.

7) Remove the water supply hose from the inlet water valve.

8) Install the new inlet water valve.

9) Replace the removed parts in the reverse order of which they were removed.

10) Close the water supply line drain valve.

11) Open the water supply line shut-off valve.

1) Check for water leaks.

13) Replace the panels in their correct positions.

14) Turn on the power supply.

2. Drain Valve

1) Turn off the power supply.

) Remove the panels and close the water supply line shut-off valve.

3) Remove the clamp and disconnect the drain water valve. Note: Water may still remain inside the evaporator. Be sure to drain the water into the drain pan.

4) Disconnect the terminals from the drain water valve.

5) Remove the drain water valve from the bracket.

6) Remove the drain pipe from the drain water valve.

7) Connect the drain pipe to the new drain water valve, and place the new drain water valve in position.

8) Connect the hose to the drain water valve and secure it with the clamp.

9) Pour water into the reservoir, and check for water leaks.

10) Open the water supply line shut-off valve.

11) Turn on the power supply.

1) Move the control switch to the "ICE" position.

13) Check for water leaks.

14) Turn off the power supply, then move the control switch to the "DRAIN" position.

15) Turn on the power supply. Make sure water is draining.

16) Turn off the power supply, then move the control switch to the "ICE" position.

17) Turn on the power supply.

18) Replace the panels in their correct positions.

Page 95

N. Removal and Replacement of Control Board

1) Turn off the power supply.

) Remove the front panel and the control box cover.

3) Disconnect the control board connectors from the control board.

4) Remove the control board.

5) Adjust the dip switches on the new control board to the factory default settings. See "II. C.4.a) Default Dip Switch Settings."

6) Install the new control board taking care not to damage it.

7) Connect the control board connectors to the new control board.

8) Replace the control box cover and front panel in their correct positions.

9) Turn on the power supply.

Page 96

VI. Cleaning and Maintenance

WARNING

CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are

securely in place after any cleaning or maintenance is done to the unit. Make sure that none have fallen into the dispenser unit/storage bin.

A. Cleaning and Sanitizing Instructions

Hoshizaki recommends cleaning and sanitizing this icemaker at least twice a year. More frequent cleaning and sanitizing, however, may be required in some existing water conditions.

WARNING

1. To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners.

. Carefully follow any instructions provided with the bottles of cleaning and

sanitizing solution.

3. Always wear liquid-proof gloves and goggles to prevent the cleaning and sanitizing solutions from coming into contact with skin or eyes.

4. After cleaning and sanitizing, do not use ice made from the cleaning and sanitizing solutions. Be careful not to leave any solution on the parts or in the dispenser unit/storage bin.

1. Cleaning Solution

IMPORTANT

For safety and maximum effectiveness, use the solution immediately after dilution.

Dilute 9.6 . oz. (0.9 l) of recommended cleaner, Hoshizaki "Scale Away" or "LIME-AWAY" (Economics Laboratory, Inc.), with 1.6 gal. (6.0 l) of warm water.

2. Cleaning Procedure

1) Turn off the power supply, then remove the front panel. Make sure the power switch is in the "ON" position, then move the control switch to the "DRAIN" position. Replace the front panel in its correct position.

) Close the water supply line shut-off valve.

3) Turn on the power supply and allow the water system to drain for 5 minutes.

4) Turn off the power supply, then remove the front and top panels. Move the power switch to the "OFF" position.

5) Remove all of the ice from the dispenser unit/storage bin.

Page 97

6) Remove the strap connecting the spout to the chute assembly, then remove the spout.

Proximity Switch

Bin Control Assembly Mount

Shaft

Plate

Packing

Chute Insulation

Ties (Hook and Loop)

Spout

Rubber O-Ring

Nylon O-Ring (if applicable)

Extruding Head

Evaporator Assembly

Packing

Actuator

Strap

Bafe

Reservoir

Chute

Fig. 14

Packing

7) Pour the cleaning solution over the extruding head until the evaporator assembly and the reservoir are full and the solution starts to overow into the drain pan. Note: If there is excess scale on the extruding head, ll the evaporator assembly and

reservoir as described above, then use a clamp on the reservoir hose between the reservoir and evaporator assembly to block ow. Pour additional cleaning uid over the extruding head until the evaporator assembly is completely full.

8) Replace the spout and strap in their correct positions.

9) Allow the icemaker to sit for about 10 minutes before operation. If you placed a clamp on the reservoir hose in step 7, remove it before operation.

10) In bad or severe water conditions, clean the oat switch assembly as described below. See Fig. 15. Otherwise, continue to step 1.

a. Remove the oat switch assembly from the reservoir cover. b. Wipe down the oat switch assembly with the cleaning solution. c. Rinse the oat switch assembly thoroughly with clean water. d. Replace the oat switch assembly in its correct position.

Float Switch Assembly

Reservoir Cover

Reservoir

Fig. 15

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11) Wipe down the infrared sensor's lens (located on the bottom of the icemaker) with the cleaning solution. See Fig. 16. Next, rinse the cleaning solution off of the infrared sensor's lens with a clean, damp cloth.

Infrared Sensor

Infrared Sensor Housing

Lens

Fig. 16

1) Move the control switch to the "ICE" position, then move the power switch to the "ON"

position. Replace the panels in their correct positions. Turn on the power supply and make ice using the solution until the icemaker stops making ice.

13) Turn off the power supply, then remove the front panel. Move the control switch to the "DRAIN" position, then replace the front panel in its correct position.

14) Turn on the power supply and allow the solution to drain for 5 minutes.

15) Turn off the power supply, then remove the front panel. Move the control switch to the "ICE" position, then replace the front panel in its correct position.

16) Open the water supply line shut-off valve, then turn on the power supply to supply water to the reservoir.

17) After the gear motor starts, turn off the power supply. Remove the front panel, then move the control switch to the "DRAIN" position. Replace the front panel in its correct position.

18) Turn on the power supply and allow the water system to drain for 5 minutes. Note: If you do not sanitize the unit, go to step 14 in "VI.A.5. Sanitizing Procedure -

Final."

19) Turn off the power supply, then close the water supply line shut-off valve.

3. Sanitizing Solution

IMPORTANT

For safety and maximum effectiveness, use the solution immediately after dilution.

Dilute .5 . oz. (74 ml or 5 tbs) of a 5.5% sodium hypochlorite solution (chlorine bleach) with 5 gal. (19 l) of warm water.

4. Sanitizing Procedure - Initial

1) Make sure the power supply is off and the water supply line shut-off valve is closed. Remove the panels, then move the power switch to the "OFF" position.

) Remove the strap connecting the spout to the chute assembly, then remove the spout.

Remove the rubber O-ring and nylon O-ring (if applicable) at the top of the cylinder and also remove the packing between the spout and the chute.

3) Pour the sanitizing solution over the extruding head until the evaporator assembly and the reservoir are full and the solution starts to overow into the drain pan.

Page 99

4) Remove the proximity switch from the chute assembly, then remove the chute assembly from the icemaker.

5) Remove the packing at the bottom of the ice chute. Remove the 3 ties and the chute insulation.

6) Remove the  bafes.

7) Remove the plate and the packing from the top of the ice chute, then remove the backup bin control assembly by sliding it slightly towards the chute opening and lifting it off.

8) Disassemble the backup bin control assembly by removing the  snap pins, shaft, and actuator.

9) Soak the spout, O-ring, packings, chute, bafes, plate, and backup bin control assembly in the sanitizing solution for 10 minutes then wipe them down.

10) Rinse the parts thoroughly with clean water.

CAUTION

If the solution is left on these parts, they will rust.

11) Replace all parts in their correct positions.

IMPORTANT

When installing the bafes, make sure that the bent surface (the one without the studs) faces the actuator so that the bent surface can guide the ice to the center of the actuator.

1) Move the control switch to the "ICE" position, then move the power switch to the "ON"

position. Replace the panels in their correct positions, then turn on the power supply. Make ice using the solution until the icemaker stops making ice.

13) Turn off the power supply, then remove the front panel. Move the control switch to the "DRAIN" position, then replace the front panel in its correct position.

14) Turn on the power supply and allow the solution to drain for 5 minutes.

15) Turn off the power supply.

5. Sanitizing Procedure - Final

1) Mix a new batch of the sanitizing solution.

) Make sure the power supply is off and the water supply line shut-off valve is closed.

Remove the front and top panels, then move the power switch to the "OFF" position.

3) Remove the strap connecting the spout to the chute assembly, then remove the spout.

4) Pour the sanitizing solution over the extruding head until the evaporator assembly and the reservoir are full and the solution starts to overow into the drain pan.

5) Replace the spout and strap in their correct positions.

6) Allow the icemaker to sit for about 10 minutes before operation.

7) Move the control switch to the "ICE" position, then move the power switch to the "ON"

Page 100

position. Replace the panels in their correct positions, then turn on the power supply. Make ice using the solution until the icemaker stops making ice.

8) Turn off the power supply, then remove the front panel. Move the control switch to the "DRAIN" position, then replace the front panel in its correct position.

9) Turn on the power supply and allow the solution to drain for 5 minutes.

10) Turn off the power supply, then remove the front panel. Move the control switch to the "ICE" position, then replace the front panel in its correct position.

11) Open the water supply line shut-off valve, then turn on the power supply to supply water to the reservoir.

1) After the gear motor starts, turn off the power supply. Remove the front panel, then

move the control switch to the "DRAIN" position. Replace the front panel in its correct position.

13) Turn on the power supply and allow the water system to drain for 5 minutes.

14) Turn off the power supply, then remove the front panel. Move the control switch to the "ICE" position, then replace the front panel in its correct position.

15) Turn on the power supply to start the automatic icemaking process. Allow the icemaker to run for about 30 minutes, then turn off the power supply.

16) Pour warm water into the dispenser unit/storage bin and melt any remaining ice. Clean the dispenser unit/storage bin liner using a neutral cleaner. Rinse thoroughly after cleaning.

17) Turn on the power supply to start the automatic icemaking process.

B. Maintenance

This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. The schedule below is a guideline. More frequent maintenance, however, may be required depending on water quality, the icemaker's environment, and local sanitation regulations. Consult with your local distributor about inspection and maintenance service. To obtain the name and phone number of your local distributor, visit www.hoshizaki.com or call Hoshizaki Technical Support at 1-800-33-1940 in the USA.

WARNING

1. Only qualied service technicians should attempt to service or maintain this icemaker.

. Disconnect power before performing maintenance.

100

Hoshizaki America FD-1001MLH-C Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important Safety Information

A. Icemaker

1. FD-1001MAH (air-cooled)

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

3. FD-1001MWH (water-cooled)

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

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

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

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

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

B. Condenser Unit

1. URC-5F

II. General Information

A. Construction

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

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

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

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

5. Ice Making Unit

B. Sequence of Operation

1. Sequence Cycles and Shutdown

a) Fill Cycle

b) Ice Purge Cycle

c) Freeze Cycle

d) Drain Cycle

e) Shutdown Cycle

2. Sequence Flow Chart

C. Control Board

1. Control Board Layout

2. Features

a) Low Water Safety

b) Ice Purge Cycle Bypass

c) Freeze Timer

d) Drain Frequency

e) Bin Control Shutdown Delay

f) High Voltage and Low Voltage Cut-outs

g) LED Lights and Alarm Safeties Chart

3. Alarm Safeties

a) Low Water Safety (1-beep alarm)

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

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

d) Freeze Timer (5-beep alarm)

e) Low Voltage (6-beep alarm)

f) High Voltage (7-beep alarm)

g) Gear Motor (8-beep alarm)

h) Bin Control (9-beep alarm)

4. Controls and Adjustments

a) Default Dip Switch Settings

b) Infrared Sensor Shutdown Delay (S1 dip switch 1, 2, & 3)

c) Drain Frequency Control (S1 dip switch 4)

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

e) Bin Control Selector (S1 dip switch 7)

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

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

D. Bin Control

E. Float Switch

III. Technical Information

A. Water Circuit and Refrigeration Circuit

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

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

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

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

B. Wiring Diagrams

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

2. FD-1001MLH(-C)

3. Sequence Wiring Diagram

a) Fill Cycle.

b) Ice Purge Cycle

c) Freeze Cycle

d) 1-in-1 Drain Cycle

e) 1-in-12 Drain Cycle

f) Infrared Sensor Shutdown

g) Mechanical Bin Control Shutdown

h) Low Water Safety

i) High Pressure Switch

C. Performance Data