Hoshizaki AM-100BAE Service Manual
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Hoshizaki AM-100BAE Service Manual

Hoshizaki AM-100BAE Service Manual

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SELF-CONTAINED CUBER
MODEL
SERVICE MANUAL
HOSHIZAKI
AM-100BAE
AM-150BAF
AM-150BWF
NO.
17EA-622 / 73106
ISSUED:
FEB. 25, 2003
REVISED: JAN. 12, 2007

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  • Page 1 17EA-622 / 73106 ISSUED: FEB. 25, 2003 REVISED: JAN. 12, 2007 HOSHIZAKI SELF-CONTAINED CUBER AM-100BAE MODEL AM-150BAF AM-150BWF SERVICE MANUAL...
  • Page 2 No such 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

    CONTENTS PAGE I. SPECIFICATIONS ------------------------------------------------------------------------------------- 1 1. DIMENSIONS/CONNECTIONS----------------------------------------------------------------- 1 [a] AM-100BAE ------------------------------------------------------------------------------------ 1 [b] AM-150BAF ------------------------------------------------------------------------------------- 2 [c] AM-150BWF ------------------------------------------------------------------------------------ 3 2. SPECIFICATIONS --------------------------------------------------------------------------------- 4 [a] AM-100BAE ------------------------------------------------------------------------------------ 4 [b] AM-150BAF ------------------------------------------------------------------------------------- 5 [c] AM-150BWF ------------------------------------------------------------------------------------ 6 II. GENERAL INFORMATION -------------------------------------------------------------------------- 7 1.
  • Page 4 [c] NO ADJUSTMENT REQUIRED ----------------------------------------------------------- 32 [d] ADJUSTMENT AT PART REPLACEMENT -------------------------------------------- 32 4. TIMING CHART ------------------------------------------------------------------------------------ 34 5. PERFORMANCE DATA------------------------------------------------------------------------- 35 [a] AM-100BAE ----------------------------------------------------------------------------------- 35 [b] AM-150BAF ------------------------------------------------------------------------------------ 36 [c] AM-150BWF ----------------------------------------------------------------------------------- 37 VI. SERVICE DIAGNOSIS ---------------------------------------------------------------------------- 38 1. NO ICE PRODUCTION -------------------------------------------------------------------------- 38 2.

  • Page 5: Specifications

    I. SPECIFICATIONS 1. DIMENSIONS/CONNECTIONS [a] AM-100BAE...

  • Page 6: B] Am-150Baf

    [b] AM-150BAF...

  • Page 7: C] Am-150Bwf

    [c] AM-150BWF...

  • Page 8: Specifications

    2. SPECIFICATIONS [a] AM-100BAE AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 6.5A (5 Min. Freeze AT 104°F/ WT 80°F) MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION Ambient Water Temp. (°F) PER 24 HR. Temp. (°F) lbs./day (kg/day) 105 (48) 103 (47)

  • Page 9: [B] Am-150Baf

    [b] AM-150BAF AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.8A (5 Min. Freeze AT 104°F/ WT 80°F) MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION Ambient Water Temp. (°F) PER 24 HR. Temp. (°F) lbs./day (kg/day) 150 (68) 140 (64) 130 (59) 140 (64) 130 (59) 120 (55)

  • Page 10: [C] Am-150Bwf

    [c] AM-150BWF AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.0A (5 Min. Freeze AT 104°F/ WT 80°F) MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION Ambient Water Temp. (°F) PER 24 HR. Temp. (°F) lbs./day (kg/day) 150 (68) 140 (64) 130 (60) 150 (68) 140 (64) 130 (60)

  • Page 11: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION [a] AM-100BAE Top Panel Front Panel (Upper) Ice Making Mechanism Bin Control Thermostat Storage Bin Slope Door Front Panel (Lower) Control Box Condenser Air Filter Tapped Hole (Leg Mounting) Control Switch Fuse...

  • Page 12: [B] Am-150Baf

    [b] AM-150BAF Top Panel Ice Making Mechanism Separator Water Tank Bin Control Thermostat Slope Door Storage Bin Front Panel (Lower) Control Box Condenser Air Filter Tapped Hole (Leg Mounting) Control Switch Fuse...

  • Page 13: [C] Am-150Bwf

    [c] AM-150BWF Top Panel Ice Making Mechanism Separator Water Tank Bin Control Thermostat Slope Door Storage Bin Front Panel (Lower) Control Box Condenser Tapped Hole (Leg Mounting) Control Switch Fuse...

  • Page 14: Icemaking Compartment

    2. ICEMAKING COMPARTMENT Bracket Evaporator Separator Ice Chute Pump Motor Water Plate Water Tank...

  • Page 15: Installation And Operating Instructions

    III. INSTALLATION AND OPERATING INSTRUCTIONS 1. CHECKS BEFORE INSTALLATION * Visually inspect the exterior of the shipping container, and any severe damage noted should be reported to the carrier. WARNING 1. Remove shipping tape(s) and packing as follows. If any left in the icemaker, it will not work properly.

  • Page 16: Location

    * The AM-100BAE icemaker requires no clearance at either side. But allow enough space at rear for water supply and drain connections and at least 12” (approx. 30 cm) clearance at front.

  • Page 17: Set Up

    3. SET UP IMPORTANT Do not place heavy objects exceeding 33 lbs (15 kg) on the Top Panel. 1) Unpack the icemaker, and remove all shipping cartons, tapes and packing BEFORE operating the unit. 2) Position the icemaker in a selected site. Clean the interior with soap and water and rinse thoroughly.

  • Page 18: Water Supply And Drain Connections

    5. WATER SUPPLY AND DRAIN CONNECTIONS WARNING To prevent damage to the freezer mechanism, do not operate this icemaker when the water supply is OFF, or if the pressure is below 10 PSIG (0.7 bar), the recommended water pressure. Stop the icemaker until proper water pressure is resumed.
  • Page 19 * A plumbing permit and services of a licensed plumber may be required in some areas. * This icemaker should be installed in accordance with applicable national, state and local regulations. AM-100BAE AM-150BAF Icemaker Water Supply Inlet 3/4” BSP Threads Brass fitting is attached to Water Supply Inlet.

  • Page 20: Final Check List

    6. FINAL CHECK LIST 1) Is the icemaker level? 2) Is the icemaker in a site where the ambient temperature is within 50°F (10°C) to 100°F (38°C) and the water temperature within 41°F (5°C) to 90°F (32°C) all year around? 3) Have all shipping tape(s), string and packing been removed from the icemaker? 4) Are all components, fasteners and thumbscrews securely in place? 5) Have all electrical and piping connections been made?

  • Page 21: Preparing The Icemaker For Long Storage (More Than 1 Day)

    8. PREPARING THE ICEMAKER FOR LONG STORAGE (more than 1 day) WARNING Drain the icemaker to prevent damage to the water supply line at subfreezing temperatures, using air or carbon dioxide. Shut off the icemaker until proper air temperature is resumed. [1] On water-cooled model only, first remove the water from the water-cooled condenser: 1) Remove the Front Panel (Lower).
  • Page 22 3) Blow out the water supply line. Note: This procedure is necessary to protect the icemaker from freezing up at subfreezing temperature. 4) Unplug the icemaker. 5) Remove all ice from the Storage Bin, and clean the Bin. 6) Drain and clean the Water Tank. See “IV. 1. [b] STORAGE BIN, SLOPE, SCOOP, ETC.” 7) Refit the Front Panel (Lower) in its correct position.

  • Page 23: Maintenance And Cleaning Instructions

    [a] WATER SYSTEM 1) Dilute approximately 5 fl. oz. (148 ml) of recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 1 gal. (3.8 lit.) of water. 2) Remove all ice from the Evaporator and the Storage Bin.
  • Page 24 8) Remove the Water Tank to drain the cleaning solution. Refit the Water Tank in its correct position. 9) Open the Shut-off Valve. 10) Move the Control Switch to the “WASH” position to circulate clean water for about 5 minutes. 11) Move the Control Switch to the “OFF”...

  • Page 25: [B] Storage Bin, Slope, Scoop, Etc

    [b] STORAGE BIN, SLOPE, SCOOP, ETC. IMPORTANT 1. Wash your hands before removing ice. Use the Plastic Scoop provided to remove ice. 2. Keep the Scoop clean. Clean it by using a neutral cleaner at least once a day, and rinse thoroughly. 3.
  • Page 26 8) Remove the Thumbscrews on both sides of the Water Tank, and pull it out toward you. Clean and sanitize the Water Tank. Water Tank Thumbscrew 9) Pull the Discharge Tube from the Water Plate. Water Plate Remove the Water Plate by pulling it toward you. Discharge Tube 10) Remove the Caps to clean and sanitize the Water Plate.

  • Page 27: Maintenance

    15) Hook each Separator on to the Mechanism Separator Base, and pull it hard toward you until it locks in place with a click. Refit all the Separators in the same way. 16) Refit the Slope in its correct position. 17) Plug in the icemaker, and move the Control Switch on the Control Box to the “ICE”...

  • Page 28: Water Valve

    3. WATER VALVE 1) Unplug the icemaker or disconnect the power source. 2) Close the water supply tap. 3) Remove the Top Panel and Door. 4) Disconnect the Water Supply Inlet from the Water Valve. 5) Remove the Mesh Filter from the Water Valve. 6) Clean the Mesh using a brush.

  • Page 29: Bin Control Thermostat

    4. BIN CONTROL THERMOSTAT Bin Control Thermostat Replacement Procedure To ensure proper operation, follow the instructions below: 1) Make a 40 mm (1.6”) diameter loop. 2) Locate the loop below the Thermostat Capillary (Bulb). 3) Manually bend the Capillary to keep it 15 mm (0.6”) forward from the through hole position on the Holder.

  • Page 30: Technical Information

    V. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] AM-100BAE Water Inlet Capillary Tube Accumulator Evaporator Water Plate Water Tank Pump Drain Pan Motor Controller Board Hot Gas Valve Drier Condenser Compressor Water Circuit Refrigeration Circuit...

  • Page 31: [B] Am-150Baf

    [b] AM-150BAF Water Inlet Expansion Valve Bulb Evaporator Water Plate Water Tank Pump Motor Drain Pan Controller Board Hot Gas Valve Compressor Pressure Switch Drier Condenser Water Circuit Refrigeration Circuit...

  • Page 32: [C] Am-150Bwf

    [c] AM-150BWF Water Inlet Expansion Valve Bulb Evaporator Water Plate Water Tank Pump Drain Pan Motor Controller Board Hot Gas Valve Compressor Pressure Switch Drier Condenser Water Regulator Water Circuit Refrigeration Circuit...

  • Page 33: Wiring Diagram

    2. WIRING DIAGRAM [a] AM-100BAE...

  • Page 34: [B] Am-150Baf

    [b] AM-150BAF...

  • Page 35: [C] Am-150Bwf

    [c] AM-150BWF...

  • Page 36: Controls

    3. CONTROLS [a] ICEMAKING CONTROL The freeze and defrost cycles are controlled by the combination of a Thermistor and an Electronic Controller. When the Evaporator cools down to a specific temperature (around 27°F), the Thermistor attached to the Evaporator senses the temperature and signals to the Electronic Controller. After the built-in Timer counts 8 minutes from the signal input, the Controller switches the contact of the built-in Relays (X1 and X2) to stop the Pump Motor and Fan Motor and to open the Hot Gas Valve and Water Valve.
  • Page 37 The Variable Resistor VR1 is for a fine adjustment of the defrost cycle completion temperature. The Variable Resistor VR2 is for a fine adjustment of the freeze cycle completion temperature. Turn VR2 clockwise for a higher temperature (WARM), i.e. ice cubes with larger diameter holes and counterclockwise for a lower temperature (COLD), i.e.

  • Page 38: Timing Chart

    4. TIMING CHART...

  • Page 39: Performance Data

    5. PERFORMANCE DATA [a] AM-100BAE APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F) PER 24 HR. 105 (48) 103 (47) 96 (44) 96 (44) 93 (42) 86 (39) 86 (39) 83 (38) 76 (35) lbs./day (kg/day) 67 (31) 66 (30)

  • Page 40: [B] Am-150Baf

    [b] AM-150BAF APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F) PER 24 HR. 150 (68) 140 (64) 130 (59) 140 (64) 130 (59) 120 (55) 130 (59) 120 (55) 110 (50) lbs./day (kg/day) 110 (51) 105 (48) 100 (45) APPROXIMATE ELECTRIC CONSUMPTION Watts...

  • Page 41: [C] Am-150Bwf

    [c] AM-150BWF APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F) PER 24 HR. 150 (68) 140 (64) 130 (60) 150 (68) 140 (64) 130 (60) 145 (66) 140 (64) 130 (60) lbs./day (kg/day) 145 (66) 135 (62) 125 (58) APPROXIMATE ELECTRIC CONSUMPTION Watts...

  • Page 42: Service Diagnosis

    VI. SERVICE DIAGNOSIS 1. NO ICE PRODUCTION PROBLEM CHECK POSSIBLE CAUSE REMEDY [1] The icemaker a) Control Switch 1. OFF position. 1. Move to ICE position. will not start. 2. Loose connections. 2. Tighten. 3. Bad contacts. 3. Check for continuity and replace.
  • Page 43 PROBLEM CHECK POSSIBLE CAUSE REMEDY [2] (Continued) 3. Refrigerant overcharged 3. Recharge. or undercharged. d) Starter 1. Defective. 1. Replace. e) Start Capacitor 1. Defective. 1. Replace. f) Power Relay 1. Bad contacts. 1. Check for continuity and (150BAF/BWF) replace. 2.

  • Page 44: Low Ice Production

    2. LOW ICE PRODUCTION PROBLEM CHECK POSSIBLE CAUSE REMEDY [1] Freeze cycle a) Water Supply 1. Low pressure. 1. Check for recommended time is too long. pressure. b) Water 1. Too high. 1. Check for recommended Temperature water temperature. c) Water Quality 1.

  • Page 45: Others

    4. OTHERS PROBLEM CHECK POSSIBLE CAUSE REMEDY [1] Icemaker will a) Bin Control 1. Fused contacts. 1. Check for continuity and not stop when Thermostat replace. Bin is filled with b) Controller Board 1. Defective. 1. Replace. ice. [2] Abnormal noise a) Pump Motor 1.

  • Page 46: Adjustment

    VII. ADJUSTMENT 1. EXPANSION VALVE - AM-150BAF/BWF ONLY The Expansion Valve is factory-adjusted. Do not adjust it except at replacement or service. Adjust the valve setting, if necessary, as follows: 1) Remove the Cap Nut. 2) Use a flat-blade screwdriver to rotate the Adjust Screw. 3) Watch holes of ice cubes produced.

  • Page 47: Water Regulating Valve - Water-Cooled Model Only

    2. WATER REGULATING VALVE - WATER-COOLED MODEL ONLY The Water Regulating Valve is factory-adjusted. Do not adjust it except at replacement or service. Adjust the valve setting, if necessary, as follows: 1) Attach a pressure gauge to high-side line, or prepare a thermometer to check Condenser drain temperature.

  • Page 48: Removal And Replacement

    VIII. REMOVAL AND REPLACEMENT 1. SERVICE FOR REFRIGERANT LINES [a] SERVICE INFORMATION 1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R134a/ R404A] The compressor must not be opened more than 30 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 49: [B] Refrigerant Recovery

    7) Evacuation, Vacuum Pump and Refrigerant Charge [R134a/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 R134a/R404A.

  • Page 50: [C] Evacuation And Recharge

    [c] EVACUATION AND RECHARGE 1) Attach Charging Hoses, a Service Manifold and a Vacuum Pump to the system. If possible, use Quick Release Connectors onto the Access Valves (especially on the high side). 2) Turn on the Vacuum Pump. 3) Allow the Vacuum Pump to pull down to a 29.9”Hg vacuum. Evacuating period depends on the pump capacity.

  • Page 51: Compressor

    16) Connect the Solderless Terminals and replace the Terminal Cover in its correct position. 17) Refit the panels in their correct positions. 18) Plug in the icemaker or connect the power source. Note: Hoshizaki recommends that Compressor starting electrics are always replaced at the same time as the Compressor.

  • Page 52: Drier

    3. DRIER 1) Unplug the icemaker or disconnect the power source. 2) Remove the Rear Mesh and Front Panel. 3) Recover the refrigerant and store it in a proper container, if required by an applicable law (See “1. [b] REFRIGERANT RECOVERY”). 4) Remove the Drier Holder, if any, and pull the Drier toward you for easy service.

  • Page 53: Evaporator

    4. EVAPORATOR 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 or disconnect the power source. 2) Remove the Rear Mesh, Door, Top and Front Panels.

  • Page 54: Hot Gas Valve

    5. HOT GAS VALVE 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 or disconnect the power source. 2) Remove the Rear Mesh and Front Panel.

  • Page 55: Pump Motor

    6. PUMP MOTOR 1) Unplug the icemaker or disconnect the power source. 2) Remove the Top Panel, Door and Front Panel. 3) Disconnect the Pump Motor leads behind the Evaporator. 4) Drain the Water Tank by compressing the plastic tabs on the Suction Tube to release the Joint.

  • Page 56: Water Valve

    8. WATER VALVE 1) Close the water supply tap. 2) Unplug the icemaker or disconnect the power source. 3) Remove the Top Panel and Front Panel. 4) Disconnect the Receptacle (leads) from the Water Valve. 5) Remove the Valve Outlet tubing. 6) Remove the Water Supply Inlet and Water Valve by releasing the two retaining screws.

  • Page 57: Thermistor For Cube Control

    10. THERMISTOR FOR CUBE CONTROL 1) Unplug the icemaker or disconnect the power source. 2) Remove the Top and Front Panels, Pipe Cover (Rear) and Control Box Cover. 3) Remove the Connectors on the Controller Board, referring to “9. CONTROLLER BOARD.” 4) Unscrew and remove the Thermistor Holder and Thermistor, located on the Evaporator.

  • Page 58: Bin Control Thermostat

    IMPORTANT When replacing the Thermistor, wrap the Thermistor Bulb with aluminum foil tape [1”(25mm) W x 0.6”(15mm) L]. 1) Wrap a turn with an overlap of 0.1 - 0.2” (3 - 5mm). 2) Make the aluminum foil tape tightly stick to the Thermistor Bulb.

  • Page 59: Expansion Valve - Am-150Baf/Bwf Only

    12. EXPANSION VALVE - AM-150BAF/BWF ONLY 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 or disconnect the power source. 2) Remove the Top, Front and Rear Mesh Panels.

  • Page 60: Water Regulating Valve - Water-Cooled Model Only

    Bulb Adjust Screw Capillary Tube Cap Nut Solder Connection Fig. 13 13. WATER REGULATING VALVE - WATER-COOLED MODEL ONLY [a] VALVE BODY 1) Unplug the icemaker or disconnect the power source. 2) Close the water supply tap. 3) Remove the Rear Mesh and Front Panel. 4) Disconnect the flare connections of the Water Regulating Valve.

  • Page 61: [B] Whole Valve

    [b] WHOLE VALVE 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 or disconnect the power source. 2) Close the water supply tap.
  • Page 62 Adjust Screw Valve Body Flare Connection Bellows Capillary Tube Fig. 14...
  • Page 63 HOSHIZAKI AMERICA, INC. 618 HIGHWAY 74 SOUTH PEACHTREE CITY, GA 30269 U.S.A. PHONE: 770-487-2331 www.hoshizakiamerica.com HOSHIZAKI ELECTRIC CO., LTD. 3-16 MINAMIYAKATA, SAKAE, TOYOAKE, AICHI 470-1194 JAPAN PHONE: 0562-97-2111...

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Am-150bwfAm-150baf

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