Hoshizaki FM-750AKE Service Manual
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Hoshizaki FM-750AKE Service Manual

Modular ice maker
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See also: Instruction Manual , Installation Manual
MODULAR ICE MAKER
MODEL
HOSHIZAKI
FM-750AKE
FM-750AKE-N
FM-1000AKE
FM-1000AKE-N
SERVICE MANUAL
NO.
F054-812
ISSUED:
AUG. 3, 2010
REVISED:

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  • Page 1 F054-812 ISSUED: AUG. 3, 2010 REVISED: HOSHIZAKI MODULAR ICE MAKER FM-750AKE MODEL FM-750AKE-N FM-1000AKE FM-1000AKE-N SERVICE MANUAL...

  • Page 2: Table Of Contents

    [b] OVERLOAD ERROR------------------------------------------------------------------------------ 1 [c] ERROR CODES AND RECORDS------------------------------------------------------------- 1 [d] OTHER INFORMATION-------------------------------------------------------------------------- 1 2. DIMENSIONS/CONNECTIONS -------------------------------------------------------------------- 2 3. SPECIFICATIONS ------------------------------------------------------------------------------------- 3 [a] FM-750AKE ----------------------------------------------------------------------------------------- 3 [b] FM-750AKE-N -------------------------------------------------------------------------------------- 4 [c] FM-1000AKE ---------------------------------------------------------------------------------------- 5 [d] FM-1000AKE-N------------------------------------------------------------------------------------- 6 4. CONSTRUCTION -------------------------------------------------------------------------------------- 7 II.
  • Page 3 [f] RESETTING COMPRESSOR OPERATING HOURS ------------------------------------46 [g] REDUCING COMPRESSOR STARTING TIME-------------------------------------------47 8. PROTECTORS ----------------------------------------------------------------------------------------47 [a] INDICATION ---------------------------------------------------------------------------------------47 9. ERROR CODES ---------------------------------------------------------------------------------------48 10. PERFORMANCE DATA -----------------------------------------------------------------------------50 [a] FM-750AKE ----------------------------------------------------------------------------------------50 [b] FM-750AKE-N -------------------------------------------------------------------------------------51 [c] FM-1000AKE ---------------------------------------------------------------------------------------52 [d] FM-1000AKE-N------------------------------------------------------------------------------------53 IV. SERVICE DIAGNOSIS -----------------------------------------------------------------------------54 1. NO ICE PRODUCTION ------------------------------------------------------------------------------54 2.
  • Page 4 [c] EVACUATION AND RECHARGE-------------------------------------------------------------58 2. BRAZING ------------------------------------------------------------------------------------------------59 3. COMPRESSOR----------------------------------------------------------------------------------------59 4. DRIER----------------------------------------------------------------------------------------------------61 5. EXPANSION VALVE ---------------------------------------------------------------------------------61 6. WATER REGULATING VALVE - WATER-COOLED MODEL ONLY --------------------62 7. EVAPORATOR ASSEMBLY -----------------------------------------------------------------------63 8. CONTROL WATER VALVE ------------------------------------------------------------------------67 9. FLUSH WATER VALVE -----------------------------------------------------------------------------67 10. CONTROLLER BOARD -----------------------------------------------------------------------------68 [a] MODIFICATION -----------------------------------------------------------------------------------68 [b] REPLACEMENT ----------------------------------------------------------------------------------68...

  • Page 5: Specifications

    I. SPECIFICATIONS 1. FEATURES [a] LOW VOLTAGE When the supply voltage is too low or surrounding high-current equipment starts up, the voltage in the icemaker may drop temporarily. In this case, the compressor will fail to start, or the gear motor will lock during the icemaking operation. The locked gear motor may apply the maximum torque to the icemaking mechanism and damage its parts.

  • Page 6: Dimensions/Connections

    2. DIMENSIONS/CONNECTIONS FM-750AKE, FM-750AKE-N FM-1000AKE, FM-1000AKE-N...

  • Page 7: Specifications

    3. SPECIFICATIONS [a] FM-750AKE...

  • Page 8: [B] Fm-750Ake-N

    [b] FM-750AKE-N...

  • Page 9: [C] Fm-1000Ake

    [c] FM-1000AKE...

  • Page 10: [D] Fm-1000Ake-N

    [d] FM-1000AKE-N...

  • Page 11: Construction

    4. CONSTRUCTION...

  • Page 12: Maintenance And Cleaning Instructions

    II. MAINTENANCE AND CLEANING INSTRUCTIONS IMPORTANT 1. This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. 2. To have the optimum performance of this icemaker, the following consumable parts need periodical inspection, maintenance and replacement: Extruding head (top bearing) Housing (lower bearing) Mechanical seal...

  • Page 13: Gear Motor

    3. GEAR MOTOR After the following hours of operation, check the gear motor for excessive noise caused by increased torque or deterioration of mechanical parts. Bearing, gear and other mechanical parts: 10,000 hours Oil seal: 5 years Note: When the output shaft oil seal is exposed to a large amount of water at one time, water may enter the gear case.

  • Page 14: Water Valve

    6. WATER VALVE 1) Disconnect the power source. 2) Close the water supply tap. 3) Disconnect the inlet hose from the water valve. 4) Remove the mesh filter from the water valve. 5) Clean the mesh using a brush. 6) Replace the mesh and inlet hose in their correct positions. 7) Open the water supply tap.

  • Page 15: Cleaning Of Water System

    7. CLEANING OF WATER SYSTEM WARNING 1. HOSHIZAKI recommends cleaning this unit at least twice a year. More frequent cleaning, however, may be required in some existing water conditions. 2. Do not touch the operation switch with damp hands. 3. Always wear rubber gloves, eye protectors, apron, etc. for safe handling of the cleaner and sanitiser.
  • Page 16 3) Remove all ice from the storage bin to avoid contamination by the cleaner. 4) Unplug the icemaker. Remove the top and front panels. 5) Remove the cover of the reservoir. Remove any loose debris or scale. 6) Carefully fill the reservoir with the solution to the overflow point. If necessary, use a small brush to clean the inside of the reservoir.

  • Page 17: Periodical Cleaning

    5) Rinse thoroughly with fresh water and a clean cloth to wipe off the solution. Close the bin door. Note: Some solutions may cause damage to the bin liner surfaces or corrosion on the metal parts. Always rinse the sanitiser unless directed otherwise by Hoshizaki guidelines.

  • Page 18: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT FM-750AKE, FM-750AKE-N FM-1000AKE, FM-1000AKE-N Pressure Switch Cut-out 3.14 + 0.15/0 MPa Cut-in 2.26 ± 0.15 MPa...

  • Page 19: Wiring Diagram

    2. WIRING DIAGRAM [a] WIRING DIAGRAM FM-750AKE(-N)
  • Page 20 FM-1000AKE(-N)

  • Page 21: [B] Control Box Layout

    [b] CONTROL BOX LAYOUT...

  • Page 22: Icemaking Mechanism

    3. ICEMAKING MECHANISM [a] EVAPORATOR (CASING) The evaporator consists of a stainless steel icemaking cylinder coiled with a refrigeration pipe and wrapped together with a polyurethane foam insulation material. Water coming from the inlet into the evaporator will be frozen into ice. The ice spout is located on top of the evaporator.

  • Page 23: [D] Housing

    compresses the sherbet ice carried up by the auger into a column shape with the path resistance. [d] HOUSING The cast bronze housing is provided with a press-fit plastic bearing inside and fixed on the bottom of the evaporator for connection with the gear motor. [e] MECHANICAL SEAL The mechanical seal on the lower auger bearing prevents icemaking water leaks into the evaporator.

  • Page 24: Water Circuit

    cap screw. The screw is provided with retaining and sealing functions, which may be reduced by the load and vibration during a freeze cycle. Do not reuse a removed socket head cap screw. Solids deposited from socket head cap screw 4.

  • Page 25: [D] Flush Water Valve

    [d] FLUSH WATER VALVE When the flush timer operates or the stop button is pressed to shut down the icemaker, the flush water valve will be energized to open and flush out the evaporator casing and reservoir (24V AC). [e] WATER REGULATOR (WATER-COOLED MODEL ONLY) See “5.

  • Page 26: Refrigeration Circuit

    a) Water-cooled Model 1) Operate the icemaker in the ICE mode. 2) Close the water supply line shut-off valve to stop water supply. 3) Open the air shut-off valve. 4) Blow the water-cooled condenser out using compressed air or CO 5) The sound of draining water is heard from the water-cooled condenser.

  • Page 27: [C] Compressor

    [c] COMPRESSOR The compressor absorbs the low-pressure refrigerant gas vaporized in the evaporator (to reduce pressure inside evaporator), compresses refrigerant into high-temperature high-pressure gas, and sends it out to the condenser. The hermetic-type compressor is efficient in refrigeration, and the refrigeration circuit is designed to endure long hours of operation.

  • Page 28: [F] Condenser Cooling Fan Motor

    < Procedure 1 > Leave the above cleaning solution inside the condenser for 12 hours. < Procedure 2 > 1) Prepare the following: Pump motor-----------------May be used for another icemaker. Dissolving tank -------------Holds at least 10L plastic bucket. Connecting hose-----------Vinyl hose ø9 x ø15 x 1.5m (x 2) Cold or warm water -------10L (50°C water is most effective) Scale remover--------------Appropriate amount Note: The cleaning procedure may vary depending on the remover used.

  • Page 29: [I] Thermostatic Expansion Valve

    [i] THERMOSTATIC EXPANSION VALVE The expansion valve throttles high-pressure liquid refrigerant into low-temperature low-pressure state by adiabatic expansion and maintains the proper amount of refrigerant supply depending on the evaporator load. The thermostatic expansion valve controls the valve position to regulate the superheat (difference between evaporating temperature and suction gas temperature).

  • Page 30: Electric Circuit

    6. ELECTRIC CIRCUIT CAUTION Reassemble all the components as they were after servicing the unit according to a service call. [a] BASIC OPERATION The icemaker starts water supply when the operation switch is moved to the “ON” position. On completion of water supply, the gear motor starts immediately. After 5 minutes the compressor starts to begin icemaking operation.

  • Page 31: [B] Timing Chart

    [b] TIMING CHART...

  • Page 32: [C] Sequence

    [c] SEQUENCE FM-750AKE, FM-750AKE-N (1) Startup - Water Supply...
  • Page 33 FM-750AKE, FM-750AKE-N (2) Startup - After completion of water supply, Gear Motor and Fan Motor start (5 min).
  • Page 34 FM-750AKE, FM-750AKE-N (3) Startup - Ice production starts...
  • Page 35 FM-750AKE, FM-750AKE-N (4) Normal Operation - Bin Control...
  • Page 36 FM-750AKE, FM-750AKE-N (5) Shutdown - Compressor stops (5 min)
  • Page 37 FM-750AKE, FM-750AKE-N (6) Shutdown - Drain...
  • Page 38 FM-1000AKE, FM-1000AKE-N (1) Startup - Water Supply...
  • Page 39 FM-1000AKE, FM-1000AKE-N (2) Startup - After completion of water supply, Gear Motor and Fan Motor start (5 min).
  • Page 40 FM-1000AKE, FM-1000AKE-N (3) Startup - Ice production starts...
  • Page 41 FM-1000AKE, FM-1000AKE-N (4) Normal Operation - Bin Control...
  • Page 42 FM-1000AKE, FM-1000AKE-N (5) Shutdown - Compressor stops (5 min)
  • Page 43 FM-1000AKE, FM-1000AKE-N (6) Shutdown - Drain...

  • Page 44: [D] Operation Board

    [d] OPERATION BOARD The operation board is provided for operation of the icemaker. See “7. OPERATION BOARD” for details. [e] CONTROLLER BOARD The icemaker is controlled by the controller board based on the following logic: a) Low Voltage Standby In a low voltage condition, the compressor and gear motor may fail to start or rotate properly due to insufficient torque.

  • Page 45: [G] Spout, Spout Cover

    passages and infrared sensor lenses in the plastic part of the bin control switch are clean. If not, wipe them clean with a soft cloth. Soft PVC Soft PVC Chute Bin Control Switch Infrared Ray Passage Infrared Sensor Lens Spout Cover Reed Switch [g] SPOUT, SPOUT COVER The spout and spout cover are connected to the...

  • Page 46: [H] Deicing Heater (Belt Heater)

    [h] DEICING HEATER (BELT HEATER) The deicing heater is provided to reduce the load of ice passing the extruding head and prevent vapor lock. If the extruding head is clogged with ice, a creaking sound will be heard, or the evaporator cylinder will expand to break the soldered joint between the cylinder and copper tube, where condensate may enter and freeze to crush the copper tube.

  • Page 47: [B] Setting Model Number

    [b] SETTING MODEL NUMBER The model number must be set at the time of replacement of the controller board. Check the model number specified on the wiring label. Improper setting may result in failure or inoperability. 1) Press and hold the maintenance B button, and move the operation switch to the “ON” position.
  • Page 48 Note: 1. The display shows the next item if the ice button is pressed before one item appears in the display. 2. The display mode is cancelled if the maintenance A button is released. 3. The software version is displayed repeatedly while the maintenance A button is pressed. Release the maintenance A button to cancel the display mode.

  • Page 49: [D] Displaying Error Log

    Repeat this three times to figure out the average. c) Model Number The display shows two digits. e.g. FM-750AKE(-N), FM-1000AKE(-N) = “05” d) Software Version The display shows the software version in six digits/symbols divided into three parts. e.g. Ver. 9-3-6 = “09”, “-3”, “-6”...

  • Page 50: [E] Resetting Error Log

    Note: 1. The display does not show the ongoing error even if the stop button is pressed while the error log is in the display. To display the ongoing error, press the stop button while “- -“ is in the display to show the end of the error log display mode [e] RESETTING ERROR LOG With the operation switch in the “OFF”...

  • Page 51: [G] Reducing Compressor Starting Time

    [g] REDUCING COMPRESSOR STARTING TIME With the power switch turned off, press and hold the maintenance A button. Move the operation switch to the “ON” position. Release the button when the display shows the ice mode. The compressor starts in 30 seconds after the water supply cycle ends 8.

  • Page 52: Error Codes

    9. ERROR CODES Interlock Errors Code Error Condition Operation Reset Check/Repair Following initial water supply, Float Switch trips Power supply, Water leak, Flush Icemaking Water at lower float level after Whole unit Turn OFF - Water Valve not Leak Gear Motor starts and stops.
  • Page 53 Code Error Condition Operation Reset Check/Repair Discharge Pipe Discharge Pipe Discharge Pipe Thermistor Circuit EH blinks. Thermistor circuit is open. Thermistor Open Power supply, Bin Control Bin Control Protective Whole unit Turn OFF - Bin Control Switch Switch Error Switch trips. stops.

  • Page 54: Performance Data

    10. PERFORMANCE DATA [a] FM-750AKE...

  • Page 55: [B] Fm-750Ake

    [b] FM-750AKE-N...

  • Page 56: [C] Fm-1000Ake

    [c] FM-1000AKE...

  • Page 57: [D] Fm-1000Ake

    [d] FM-1000AKE-N...

  • Page 58: Service Diagnosis

    IV. SERVICE DIAGNOSIS Display error records by operating the operation board (see “III. 7. [d] DISPLAYING ERROR LOG”). Check for a possible cause and service the unit. 1. NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker a) Power supply 1.

  • Page 59: Low Ice Production

    PROBLEM POSSIBLE CAUSE REMEDY [3] (Continued) c) Controller board 1. Defective. 1. Replace. d) Pressure switch 1. Dirty condenser fins. 1. Clean. 2. Ambient temperature 2. Check for recommended too warm. temperature. 3. Fan not rotating. 3. See 3 - [1] - a). 4.

  • Page 60: Others

    PROBLEM POSSIBLE CAUSE REMEDY [1] (Continued) b) High-side 1. Dirty air filter or 1. Clean. pressure too high condenser. 2. Ambient or condenser 2. Check for recommended water temperature too temperature. warm. 3. Condenser water 3. Check and get recommended pressure too low or off.

  • Page 61: Removal And Replacement Of Components

    V. REMOVAL AND REPLACEMENT 1. SERVICE FOR REFRIGERANT LINES [a] SERVICE INFORMATION 1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R404A] The compressor must not be opened more than 15 minutes in replacement or service. Do not mix lubricants of different compressors even if both are charged with the same refrigerant, except when they use the same lubricant.

  • Page 62: [B] Refrigerant Recovery

    7) Evacuation, Vacuum Pump and Refrigerant Charge [R404A] Never allow the oil in the vacuum pump to flow backward. The vacuum level and vacuum pump may be the same as those for the current refrigerants. However, the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for R404A.

  • Page 63: Brazing

    valve. When pressure reduces on the low side, disconnect the low side charging line and cap off the access valve. 8) Always cap the access valves to prevent a refrigerant leak. Tighten the cap to a torque of 9.81 - 12.26 Nm. 9) Always thoroughly leak test all joints and valve caps.
  • Page 64 3) Remove the terminal cover on the compressor, and disconnect the compressor wiring. 4) Recover the refrigerant and store it in a proper container, if required by an applicable law (See “1. [b] REFRIGERANT RECOVERY”). 5) Remove the discharge, suction and access pipes from the compressor using brazing equipment.

  • Page 65: Drier

    4. DRIER IMPORTANT Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made. 1) Disconnect the power source. 2) Remove the front panel. 3) Recover the refrigerant and store it in a proper container, if required by an applicable law (See “1.

  • Page 66: Water Regulating Valve - Water-Cooled Model Only

    5) Remove the expansion valve cover, and disconnect the expansion valve using brazing equipment. 6) Braze the new expansion valve with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar. WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating.

  • Page 67: Evaporator Assembly

    7) Remove the screws and the valve from the bracket. 8) Install the new valve, and braze the capillary tube. 9) Install the new drier. 10) Check for leaks using nitrogen gas (10 bar) and soap bubbles. 11) Connect the flare-connections. 12) Evacuate the system, and charge it with refrigerant.
  • Page 68 Note: Replacing the bearing needs a fitting tool. If it is not available, replace the whole extruding head. AUGER 11) Lift out the auger. Check the top and bottom areas in contact with the bearings. If the surface is scratched or pitted, replace the auger. Check the blade edge of the auger. If it is scratched or worn where it has contacted the evaporator, replace it.
  • Page 69 BEARING - LOWER AND MECHANICAL SEAL 19) The mechanical seal consists of two parts. One part rotates with the auger, the other is static and is fitted into a top recess in the housing. If the contact surfaces of these two parts become worn or scratched, the mechanical seal may leak water and should be replaced.
  • Page 70 Dowel Pin Screw Screw Washer Washer Cutter Cutter Extruding Extruding Auger Head Head Spout Gasket Mechanical Seal Flange Screw w/Washer O-Ring Gear Motor Cover Belt Heater Hex Head Bolt w/Washer Sealing Bolt Housing Evaporator Coupling - Spline Screw Gear Motor...

  • Page 71: Control Water Valve

    8. CONTROL WATER VALVE 1) Disconnect the power source. 2) Close the water supply tap. 3) Remove the panels. 4) Disconnect the terminals from the control water valve. 5) Remove the cover - reservoir Inlet from the control water valve. 6) Loosen the fitting nut on the control water valve Inlets, and remove the control water valve.

  • Page 72: Controller Board

    9) Connect the hose to the flush water valve, and secure it with the clamp. 10) Pour water into the reservoir, and check for water leaks on the flush water valve. 11) Open the water supply tap. 12) Connect the power source. 13) Check for water leaks.
  • Page 73 6) Install the new controller board and reassemble the control box in the reverse order of the removal procedure. 7) Replace the front panel in its correct position. 8) Connect the power source.

This manual is also suitable for:

Fm-1000akeFm-750ake-nFm-1000ake-n

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