Hoshizaki F-500BAF Service Manual
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Hoshizaki F-500BAF Service Manual

Hoshizaki F-500BAF Service Manual

Self-contained flaker
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Self-Contained Flaker
Model
F-500BAF
SERVICE MANUAL
Number: 73074
Issued: 3-2-1999
Revised: 12-26-2003

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Summary of Contents for Hoshizaki F-500BAF

  • Page 1 Hoshizaki Hoshizaki America, Inc. Self-Contained Flaker Model F-500BAF SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com Number: 73074 Issued: 3-2-1999 Revised: 12-26-2003...
  • Page 2 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.

  • Page 3: Table Of Contents

    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 ....................
  • Page 4 VI. Cleaning and Maintenance ..................41 1. Preparing the Icemaker for Long Storage ..............41 2. Cleaning and Sanitizing Instructions ................42 [a] Cleaning Solution ....................42 [b] Cleaning Procedure .................... 42 [c] Sanitizing Solution ....................43 [d] Sanitizing Procedure - Initial ................44 [e] Sanitizing Procedure - Final ................

  • Page 5: Specifications

    I. Specifications F-500BAF AC S UP P LY VOLTAGE 115/ 60/ 1 COMP RE S S OR 120 V 7.9 RLA 51 LRA GE AR MOTOR 120 V 1.6 FLA 1/ 6 HP FAN MOTOR 120 V 0.85 FLA 1/ 15 HP...

  • Page 6: F-500Baf-C

    F-500BAF-C AC S UP P LY VOLTAGE 115/ 60/ 1 COMP RE S S OR 120 V 7.9 RLA 51 LRA GE AR MOTOR 120 V 1.6 FLA 1/ 6 HP FAN MOTOR 120 V 0.85 FLA 1/ 15 HP...

  • Page 7: General Information

    II. General Information 1. Construction F-500BAF, F-500BAF-C Top Panel Side Panel Side Panel Sliding Door Water Supply Inlet Front Panel Control Water Valve Spout Reservoir Gear Motor Evaporator Access Valve Condenser Compressor Condenser Fan Control Box...

  • Page 8: Ice Making Unit

    2. Ice Making Unit...

  • Page 9: Control Box Layout

    3. Control Box Layout F-500BAF, F-500BAF-C PRESSURE SWITCH CONNECTOR TRANSFORMER CONTROL TIMER FLUSH VALVE CONTROL RELAY FLUSH STARTER FLUSH SWITCH POWER SWITCH CAPACITOR FUSE CIRCUIT PROTECT RELAY CIRCUIT BREAKER START CAPACITOR GEAR MOTOR PROTECT RELAY CAPACITOR FOR CAPACITOR FOR GEAR MOTOR...

  • Page 10: Timer Board

    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.

  • Page 11: [C] Sequence

    Compressor Relay Gear Motor Relay Fig. 1 [c] Sequence Fig. 2...
  • Page 12 ± ± ± ± ± Fig. 3...
  • Page 13 Functions of Terminals 1) Terminals 1, 2 Power supply AC 24V. 2) Terminals 3, 4 Control X (GM) and X (CM) Relays. When closed, energize X (GM) in 1 sec. and X (CM) in 60 sec. When opened, de-energize X (GM) in 150 sec.

  • Page 14: Technical Information

    III. Technical Information 1. Water Circuit and Refrigerant Circuit F-500BAF, F-500BAF-C CONTROL SPOUT WATER VALVE FLOAT SWITCH WATER WATER LEVEL INLET EVAPORATOR RESERVOIR EXPANSION VALVE GEAR OVERFLOW MOTOR FLUSH WATER VALVE DRAIN PAN DRAIN OUTLET DRAIN PAN DRIER CONDENSER CONDENSER...

  • Page 15: Wiring Diagram

    2. Wiring Diagram F-500BAF, F-500BAF-C...

  • Page 16: Sequence Of Electrical Circuit

    3. Sequence of Electrical Circuit F-500BAF, F-500BAF-C [a] When power switch is moved to "ON" position and flush switch to "ICE" position, water starts to be supplied to reservoir. (F-500BAF(-C))
  • Page 17 [b] When reservoir has been filled up, gear motor starts immediately. (F-500BAF(-C))
  • Page 18 [c] Compressor starts about 60 sec. after gear motor starts. (F-500BAF(-C))
  • Page 19 [d] Compressor stops about 90 sec. after bin control operates. Gear motor stops about 60 sec. later, and water is drained from the water circuit. Water can be also drained by moving flush switch to "FLUSH" position. (F-500BAF(-C))
  • Page 20 [e] When 208 - 230V are supplied to the power supply due to miswiring, circuit protect relay operates, and the icemaker does not run. (F-500BAF(-C))

  • Page 21: Timing Chart

    4. Timing Chart Miswiring. Circuit Protect Relay operates. Proper wiring. The unit starts. BIN CONTROL 1. CIRCUIT PROTECT RELAY UPPER 2. WATER LEVEL LOWER BOTTOM UPPER 3. FLOAT SWITCH LOWER 4. WATER CONTROL RELAY 5. CONTROL WATER VALVE 6. FLUSH RELAY FLUSH 7.
  • Page 22 LOW WATER CONDENSER FAN FAILURE 1. CIRCUIT PROTECT RELAY UPPER LOWER 2. WATER LEVEL BOTTOM UPPER 3. FLOAT SWITCH LOWER 4. WATER CONTROL RELAY 5. CONTROL WATER VALVE 6. FLUSH RELAY FLUSH 7. FLUSH SWITCH 8. FLUSH WATER VALVE 9. BIN CONTROL 150 sec 1 sec 10.
  • Page 23 FLUSH SWITCH FLUSH 1. CIRCUIT PROTECT RELAY UPPER LOWER 2. WATER LEVEL BOTTOM UPPER 3. FLOAT SWITCH LOWER 4. WATER CONTROL RELAY 5. CONTROL WATER VALVE 6. FLUSH RELAY FLUSH 7. FLUSH SWITCH 8. FLUSH WATER VALVE 9. BIN CONTROL 150 sec 1 sec 10.

  • Page 24: Performance Data

    5. Performance Data F-500BAF APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F) PER 24 HR. *478 *(217) (208) (199) (190) (182) (174) (166) *359 *(163) (152) lbs./day (kg/day) (145) (139) *287 *(130) APPROXIMATE ELECTRIC *854 CONSUMPTION *900 watts *930...

  • Page 25: F-500Baf-C

    F-500BAF-C APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F) PER 24 HR. *431 *(196) (188) (181) (173) (166) (159) (152) *333 *(151) (140) lbs./day (kg/day) (134) (128) *263 *(119) APPROXIMATE ELECTRIC *864 CONSUMPTION *902 watts *922 APPROXIMATE WATER *(196)

  • Page 26: Service Diagnosis

    IV. Service Diagnosis 1. No Ice Production PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker will a) Power Supply 1. OFF position. 1. Move to ON position. not start. 2. Loose connection. 2. Tighten. 3. Bad contacts. 3. Check for continuity and replace.
  • Page 27 PROBLEM POSSIBLE CAUSE REMEDY d) Gear Motor Protect 1. Coil winding opened. 1. Replace. Relay 2. Bad contacts. 2. Check for continuity and replace. e) Control Timer 1. Broken. 1. Replace. (Printed Circuit Board) [4] Gear Motor starts, a) Pressure Switch 1.
  • Page 28 PROBLEM POSSIBLE CAUSE REMEDY e) Compressor 1. Loose connections. 1. Tighten. 2. Motor winding 2. Replace. opened or grounded. 3. Motor Protector 3. Find out the cause of tripped. overheat or overcurrent. Power Supply 1. Circuit Ampacity too 1. Install a larger-sized low.

  • Page 29: Low Ice Production

    2. Low Ice Production PROBLEM POSSIBLE CAUSE REMEDY [1] Low ice production a) Refrigerant Line 1. Gas leaks. 1. See "1. [5] a) Refrigerant Line." 2. Refrigerant line 2. Replace the clogged clogged. component. 3. Overcharged. 3. Recharge. b) High-side Pressure 1.

  • Page 30: Other

    3. Other PROBLEM POSSIBLE CAUSE REMEDY [1] Abnormal noise a) Fan Motor 1. Bearing worn out. 1. Replace. 2. Fan blade deformed. 2. Replace fan blade. 3. Fan blade does not 3. Replace. move freely. b) Compressor 1. Bearings worn out, 1.

  • Page 31: Removal And Replacement Of Components

    V. Removal and Replacement of Components IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORTANT 1. 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.

  • Page 32: Brazing

    5) Disconnect the vacuum pump, and attach a refrigerant service cylinder to the high- side line. Remember to loosen the connection, and purge the air from the hose. See the nameplate for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used.

  • Page 33: Removal And Replacement Of Compressor

    3. Removal and Replacement of Compressor IMPORTANT Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made. 1) Unplug the icemaker. 2) Remove the panels. 2) Remove the terminal cover on the compressor, and disconnect the compressor wiring.

  • Page 34: Removal And Replacement Of Drier

    13) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles. 14) Evacuate the system, and charge it with refrigerant. See the nameplate for the required refrigerant charge and type. 15) Connect the terminals to the compressor, and replace the terminal cover in its correct position.

  • Page 35: Removal And Replacement Of Expansion Valve

    5. Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigerant circuit exceeds the drier capacity and freezes up at the expansion valve. Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repairs or replacement have been made.

  • Page 36: Removal And Replacement Of Evaporator Assembly

    6. Removal and Replacement of Evaporator Assembly 1) Drain the water from the evaporator by switching the flush switch to “FLUSH” on the control box. 2) Unplug the icemaker. 3) Remove the panels. 4) Remove the three thumbscrews and take off the spout from the evaporator. Cutter 5) Loosen the cutter by a wrench and remove it.
  • Page 37 Evaporator Note: Skip the following steps 10) through 12) when the evaporator does not need replacement. 10) Recover the refrigerant and store it in an approved container, if required by an applicable law. IMPORTANT Always install a new drier every time the sealed refrigeration system is opened.
  • Page 38 Gear Motor 20) Remove the coupling-spline on the gear motor shaft. 21) Remove the three bolts securing the gear motor. 22) Assemble the removed parts in the reverse order of the above procedure. WARNING Be careful not to scratch the surface of the O-ring, or it may cause water leaks. Handle the mechanical seal with care not to scratch nor to contaminate its contact surface.
  • Page 39 Cutter Extruding Head Auger Socket Head Cap Screw Spring Retainer Evaporator Mechanical Seal Hexagon Socket Cap Bolt with O-ring Washer Bearing- Lower Coupling- Spline Barrier Gear Motor...

  • Page 40: Removal And Replacement Of Fan Motor

    7. Removal and Replacement of Fan Motor 1) Unplug the icemaker. 2) Remove the panels. 3) Remove the wire connectors from the fan motor leads. 4) Remove the fan motor bracket and fan motor. 5) Install the new fan motor. 6) Replace the fan motor bracket and the wire connectors.

  • Page 41: Cleaning And Maintenance

    VI. Cleaning and Maintenance IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. 1. Preparing the Icemaker for Long Storage WARNING When shutting off the icemaker for an extended time, drain out all water from the water line and remove the ice from the storage bin.

  • Page 42: Cleaning And Sanitizing Instructions

    [a] Cleaning Solution Dilute 4.8 fl. oz. (142 ml) of recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 0.8 gallons (3 l) of warm water. This is a minimum amount. Make more solution if necessary.

  • Page 43: [C] Sanitizing Solution

    8) Remove the thumbscrews attaching spout (A) to the evaporator assembly and lift off spout (A) and spout packing (A). 9) Pour the cleaning solution over the extruding head until the evaporator assembly and the reservoir are filled and the solution starts to overflow into the drain pan. Note: If there is excess scale on the extruding head, fill the evaporator assembly and reservoir as described above, then use a clamp on the reservoir hose between the reservoir and evaporator assembly to block flow.

  • Page 44: [D] Sanitizing Procedure - Initial

    [d] Sanitizing Procedure - Initial 1) Close the water supply line shut-off valve. 2) In the storage bin, remove the thumbscrews attaching spout (B), then remove spout (B) and spout packing (B). 3) Remove the thumbscrews attaching spout (A) to the evaporator assembly and lift off spout (A) and spout packing (A), and the cylinder packing.
  • Page 45 6) Remove the thumbscrews attaching spout (A) to the evaporator assembly and lift off spout (A) and spout packing (A). 7) Pour the sanitizing solution over the extruding head until the evaporator assembly and the reservoir are filled and the solution starts to overflow into the drain pan. 8) Using the thumbscrews, replace spouts (A) and (B) and spout packings (A) and (B) in their correct positions.

  • Page 46: Maintenance Instructions

    More frequent inspection and maintenance are recommended. Consult with your local distributor about inspection and maintenance service. To obtain the name and phone number of your local distributor, call Hoshizaki Technical Support at 1-800-233-1940 in the USA. 1) Stainless Steel Exterior To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth.
  • Page 47 3) Air Filter A plastic mesh air filter removes dirt or dust from the air, and keeps the condenser from getting clogged. As the filter gets clogged, the icemaker’s performance will be reduced. Check the filter at least twice a month. When clogged, use warm water and a neutral cleaner to wash the filter.

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