Hoshizaki American, Inc. F-500BAF Service Manual

NO:
ISSUED:
REVISED:

73074
MAR. 2, 1999
DEC. 26, 2003

HOSHIZAKI

SELF-CONTAINED FLAKER

MODEL

SERVICE MANUAL

F-500BAF/-C

IMPORTANT

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

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

Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call or write to the HOSHIZAKI Technical Support Department for
assistance.

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

Attn: HOSHIZAKI Technical Support Department

Phone: [phone] Technical Service

[phone]

Fax: [phone]

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

information:

• Model Number

• Serial Number

• Complete and detailed explanation of the problem

2

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

CONTENTS

PAGE

I. SPECIFICATIONS .................................................................................................... 5

F-500BAF............................................................................................................... 5

F-500BAF-C ........................................................................................................... 6

II. GENERAL INFORMATION ...................................................................................... 7

1. CONSTRUCTION................................................................................................... 7

F-500BAF, F-500BAF-C......................................................................................... 7

2. ICE MAKING UNIT ................................................................................................. 8

3. CONTROL BOX LAYOUT ...................................................................................... 9

F-500BAF, F-500BAF-C......................................................................................... 9

4. TIMER BOARD..................................................................................................... 10

[a] SOLID-STATE CONTROL .............................................................................. 10

[b] TIMER BOARD ............................................................................................... 10

[c] SEQUENCE .................................................................................................... 11

III. TECHNICAL INFORMATION................................................................................ 14

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT .............................................. 14

F-500BAF, F-500BAF-C....................................................................................... 1 4

2. WIRING DIAGRAM .............................................................................................. 1 5

F-500BAF, F-500BAF-C....................................................................................... 1 5

3. SEQUENCE OF ELECTRICAL CIRCUIT............................................................. 16

F-500BAF, F-500BAF-C....................................................................................... 1 6

4. TIMING CHART.................................................................................................... 21

5. PERFORMANCE DATA ....................................................................................... 24

F-500BAF............................................................................................................. 24

F-500BAF-C ......................................................................................................... 25

IV. SERVICE DIAGNOSIS ......................................................................................... 26

1. NO ICE PRODUCTION ........................................................................................ 26

2. LOW ICE PRODUCTION ..................................................................................... 29

3. OTHERS............................................................................................................... 30

V. REMOVAL AND REPLACEMENT OF COMPONENTS ........................................ 31

1. SERVICE FOR REFRIGERANT LINES ............................................................... 31

[a] REFRIGERANT RECOVERY ......................................................................... 3 1

[b] EVACUATION AND RECHARGE ................................................................... 31

2. BRAZING.............................................................................................................. 32

3. REMOVAL AND REPLACEMENT OF COMPRESSOR....................................... 33

3

4. REMOVAL AND REPLACEMENT OF DRIER ..................................................... 34

5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE............................... 35

6. REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY ................... 36

7. REMOVAL AND REPLACEMENT OF FAN MOTOR ........................................... 40

8. REMOVAL AND REPLACEMENT OF CONTROL WATER VALVE .................... 4 0

VI. MAINTENANCE AND CLEANING INSTRUCTIONS............................................ 41

1. PREPARING THE ICEMAKER FOR LONG STORAGE ...................................... 41

2. CLEANING INSTRUCTIONS ............................................................................... 42

3. MAINTENANCE ................................................................................................... 46

4

I. SPECIFICATIONS

F-500BAF

AC SUPPLY VOLTAGE 115/60/1
COMPRESSOR 120 V 7.9 RLA 51 LRA
GEAR MOTOR 120 V 1.6 FLA 1/6 HP
FAN MOTOR 120 V 0.85 FLA 1/15 HP
OTHER 120 V 0.03 A
MAXIMUM FUSE SIZE 20 A
MAX. HACR BREAKER (USA ONLY) 20 A
MAX. CIRC. BREAKER (CANADA ONLY) 20 A
MINIMUM CIRCUIT AMPACITY 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F)507090
lbs./day ( kg/day ) 70 * 478 (217) 458 (208) 438 (199)
Reference without *marks 80 419 (190) 400 (182) 383 (174)

90 366 (166) * 359 (163) 335 (152)

100 320 (145) 306 (139) * 287 (130)
SHAPE OF ICE Flake
ICE QUALITY Approx. 70%, Ice (90/70°F, Conductivity 200 µs/cm)
APPROXIMATE STORAGE CAPACITY 250 lbs.
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 900 (6.0) 854 (4.3)
POTABLE WATER 43 (12) 57 (12)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (Wx DxH) 38" x 29" x 36" (965 x 735 x 915 mm)
EXTERIOR FINISH PVC Coated Galvanized St eel; Galvanized Steel (Rear);

Stainless Steel (Top)
WEIGHT Net 210 lbs. ( 95 kg ), Shipping 245 lbs. ( 111 kg )
CONNECTIONS - ELECTRIC Permanent Connection

- W ATER SUPPLY Inlet 1/2" FPT

- DRAIN Drain Pan 3/4" FPT

Bin Drain 3/4" FPT
ICE MAKING SYSTEM Auger type
HARVESTING SYSTEM Direct Driven Auger ( 1/6 HP Gear Motor )
ICE MAKING WATER CONTROL Float Switch
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. )
COMPRESSOR Hermetic, Model RS43C1E-CAA
CONDENSER Air-cooled, Fin and tube type
EVAPORATOR Copper Tube on Cylinder
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R-404A, 1 lb. (470 g)
DESIGN PRESSURE High 460 PSIG, Low 290 PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-off Relay
COMPRESSOR PROTECTION Auto-reset Overload Protector
GEAR MOTOR PROTECTION Manual reset Circuit Breaker
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch and Timer
ACCESSORIES - SUPPLIED Ice Scoop, Spare Fuse

- REQUIRED Legs
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V

AMBIENT TEMP. 45 - 100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG
DRAWING NO. (DIMENSIONS) 339850---

We reserve the right to make changes in specifications and design without prior notice.

5

F-500BAF-C

AC SUPPLY VOLTAGE 115/60/1
COMPRESSOR 120 V 7.9 RLA 51 LRA
GEAR MOTOR 120 V 1.6 FLA 1/6 HP
FAN MOTOR 120 V 0.85 FLA 1/15 HP
OTHER 120 V 0.03 A
MAXIMUM FUSE SIZE 20 A
MAX. HACR BREAKER (USA ONLY) 20 A
MAX. CIRC. BREAKER (CANADA ONLY) 20 A
MINIMUM CIRCUIT AMPACITY 20 A
APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)
PER 24 HR. Temp.(°F) 50 70 90
lbs./day ( kg/day ) 70 * 431 (196) 415 (188) 398 (181)
Reference without *marks 80 381 (173) 365 (166) 350 (159)

90 336 (152) * 333 (151) 308 (140)

100 295 (134) 283 (128) * 263 (119)

SHAPE OF ICE Cubelet
ICE QUALITY Approx. 80%, Ice (90/70°F, Conductivity 200 µs/cm)
APPROXIMATE STORAGE CAPACITY 250 lbs.
ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F
ELECTRIC W (kWH/100 lbs.) 903 (6.5) 864 (4.8)
POTABLE WATER 40 (12) 52 (12)
gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH) 38" x 29" x 36" (965 x 735 x 915 mm)
EXTERIOR FINISH PVC Coated Galvanized Steel; Galvanized Steel (Rear);

Stainless Steel (Top)
WEIGHT Net 210 lbs. ( 95 kg ), Shipping 245 lbs. ( 111 kg )
CONNECTIONS - ELECTRIC Permanent Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Drain Pan 3/4" FPT

Bin Drain 3/4" FPT
ICE MAKING SYSTEM Auger type
HARVESTING SYSTEM Direct Driven Auger ( 1/6 HP Gear Motor )
ICE MAKING WATER CONTROL Float Switch
COOLING WATER CONTROL N/A
BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. )
COMPRESSOR Hermetic, Model RS43C1E-CAA
CONDENSER Air-cooled, Fin and tube type
EVAPORATOR Copper Tube on Cylinder
REFRIGERANT CONTROL Thermostatic Expansion Valve
REFRIGERANT CHARGE R-404A, 1 lb. (470 g)
DESIGN PRESSURE High 460 PSIG, Low 290 PSIG
P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-off Relay
COMPRESSOR PROTECTION Auto-reset Overload Protector
GEAR MOTOR PROTECTION Manual reset Circuit Breaker
REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch
LOW WATER PROTECTION Float Switch and Timer
ACCESSORIES - SUPPLIED Ice Scoop, Spare Fuse

- REQUIRED Legs
OPERATING CONDITIONS VOLTAGE RANGE 104 - 127 V

AMBIENT TEMP. 45 - 100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG
DRAWING NO. (DIMENSIONS) 339850---

We reserve the right to make changes in specifications and design without prior notice.

6

II. GENERAL INFORMATION

1. CONSTRUCTION

F-500BAF, F-500BAF-C

Side Panel

Top Panel

Side Panel

Sliding Door

Front Panel

Spout

Gear Motor

Access Valve

Compressor

Control Box

Water Supply Inlet

Control Water Valve

Reservoir

Evaporator

Condenser

Condenser Fan

7

2. ICE MAKING UNIT

8

3. CONTROL BOX LAYOUT

F-500BAF, F-500BAF-C

PRESSURE
SWITCH

TRANSFORMER

FLUSH V ALVE
CONTROL RELAY

STARTER

RUN
CAPACITOR

CONNECTOR

CONTROL
TIMER

FLUSH

FLUSH SWITCH

ICE

ON

POWER SWITCH

OFF

FUSE

CIRCUIT PROTECT
RELAY

START
CAPACITOR

GEAR MOTOR
PROTECT RELAY

WATER CONTROL
RELAY

CAPACITOR FOR
GEAR MOTOR

CAPACITOR FOR
FAN MOTOR

CIRCUIT
BREAKER

Note: The above component names are identical with the Wiring Label, but not with the Parts

List.

9

4. TIMER BOARD

[a] SOLID-STATE CONTROL

1) A HOSHIZAKI exclusive solid-state control is employed in the self-contained flaker
icemakers.

2) A Printed Circuit Board (hereafter called “Timer Board”) includes a stable and high qual­ity control system.

3) All models are pre-tested and factory adjusted.

[b] TIMER BOARD

CA UTION

1. Fragile, handle very carefully.

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

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

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

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

The icemaker is controlled by the Timer Board for the following purposes:

1) To prevent the Gear Motor and the Compressor from starting or stopping simulta­neously.

2) To reduce remaining ice in the refrigeration casing.

3) To protect the unit in case of low water and low water pressure.

4) To protect the unit in case the Bin Control causes chattering.

10

[C] SEQUENCE

Fig. 1

Fig. 2

11

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GNITARzH06/05CAV42

1T.ces51±06
2T.ces22±09
3T.ces54±051
4Tsselro.ces1
5T%07±.ces7.6
6T%07±.ces7.6

Fig. 3

12

Functions of Terminals

1) Terminals 1, 2
Power supply AC 24V.

2) Terminals 3, 4
Control X1 (GM) and X2 (CM) Relays.
When closed, energize X1 (GM) in 1 sec. and X2 (CM) in 60 sec.
When opened, de-energize X1 (GM) in 150 sec. and X2 (CM) in 90 sec.

3) Terminals 5, 6
Control X1 (GM) and X2 (CM) Relays.
When opened, de-energize X1 (GM) and X2 (CM) immediately.
When closed again, energize X1 (GM) in 1 sec. and X2 (CM) in 60 sec.

4) Terminals 7, 8, 9
X1 (GM) contacts.
8 is a movable contact, 7 is a make contact, and 9 is a break contact.

5) Terminals 10, 11
Control X2 (CM) Relays.
When opened, de-energize X2 (CM) immediately.
When closed, energize X2 (CM) immediately.

Note: 1. X2 Relay is a single pole, normally open relay, and its terminals are mounted

on the relay itself.

2. The above operation times are median. See Fig. 3 for details.

13

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

F-500BAF, F-500BAF-C

WATER
INLET

DRAIN
OUTLET

CONTROL
WATER
VALVE

RESERVOIR

OVERFLOW

FLOAT
SWITCH

WATER LEVEL

EVAPORATOR

GEAR
MOTOR

DRAIN PAN

DRAIN PAN

SPOUT

EXPANSION
VALVE

FLUSH
WATER
VALVE

CONDENSER

DRIER

CONDENSER
FAN MOTOR

ACCESS
VALVE

WATER CIRCUIT

REFRIGERANT CIRCUIT

PRESSURE
SWITCH

ACCESS
VALVE

COMPRESSOR

14

2. WIRING DIAGRAM

F-500BAF, F-500BAF-C

15