Hoshizaki MODULAR CUBELET SERENITY SERIES FS-1022MLH-C Service Manual
Modular cubelet serenity series including condensing unit
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Summary of Contents for Hoshizaki MODULAR CUBELET SERENITY SERIES FS-1022MLH-C
- Page 1 Hoshizaki America, Inc. “A Superior Degree of Reliability” www.hoshizaki.com Modular Cubelet Serenity Series Model FS-1022MLH-C Including Condensing Unit Model SRC-10H SERVICE MANUAL Number: 73186 Issued: 6-9-2011...
- Page 2 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, write, or send an e-mail message to the Hoshizaki Technical Support Department for assistance. HOSHIZAKI AMERICA, INC.
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Page 3: Table Of Contents
This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified 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. - Page 4 IV. Service Diagnosis ... 26 A. Ice Production Check ... 26 B. Diagnostic Procedure ... 26 C. Control Board Check ... 30 D. Bin Control Check ... 33 1. Infrared Sensor Check ... 33 2. Mechanical Backup Bin Control Check ... 34 E.
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Page 5: Important Safety Information
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. - Page 6 For FS - Continued • To reduce the risk of electric shock, do not touch the plug or power switch with damp hands. • Do not use a unit with a damaged power cord. The power cord should not be altered, jerked, bundled, weighed down, pinched, or tangled. Such actions could result in electric shock or fire. To unplug the unit, be sure to pull the plug, not the cord, and do not jerk the cord. • Do not place fingers or any other objects into the ice discharge opening.
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Page 7: Specifications
I. Specifications A. Icemaker 1. FS-1022MLH-C AC SUPPLY VOLTAGE GEAR MOTOR OTHER MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR. lb./day (kg/day) Reference without *marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC &... -
Page 8: Condensing Unit
B. Condensing Unit 1. SRC-10H AC SUPPLY VOLTAGE COMPRESSOR FAN MOTOR OTHER MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY EXTERIOR DIMENSIONS (WxDxH) DIMENSIONS WITH LEGS (WxDxH) EXTERIOR FINISH WEIGHT (Approximate) CONNECTIONS - ELECTRIC - REFRIGERATION CIRCUIT COMPRESSOR... -
Page 9: General Information
II. General Information A. Construction 1. Icemaker a) FS-1022MLH-C Inlet Water Valve Float Switch Reservoir Ice Chute Strainer Pump-Down Solenoid Valve High-Side Service Valve Low-Side Service Valve Infrared Sensor Mechanical Backup Bin Control Spout Gear Motor Power Cord Icemaking Unit: Cutter Extruding Head Evaporator... -
Page 10: Condensing Unit
2. Condensing Unit a) SRC-10H Headmaster (C.P.R.) Receiver High-Side Service Valve Liquid Line Suction Line Connection Connection Control Low-Pressure Switch Condenser Fan Motor Compressor Control Box Safety Low-Pressure Switch High-Pressure Switch... -
Page 11: Icemaking Unit
3. Icemaking Unit Extruding Head Upper Bearing Evaporator Heater Auger Mechanical Seal O-Ring Spline Coupling Socket Head Cap Screw and Split Lock Washer Cutter Washer Seal Bolts and Washers Evaporator Socket Head Cap Screw and Split Lock Washer Housing-Lower Bearing Hex Bolt and Washer Gear Motor... -
Page 12: Sequence Of Operation
B. Sequence of Operation The steps in the sequence are as outlined below. This unit utilizes a control board to switch the icemaker 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, control board "POWER OK" LED and infrared sensor green LED come on. The "POWER OK" LED remains on constantly. If the infrared sensor yellow LED is on or flashing, move ice away from the infrared sensor lens. This system utilizes a pump-down solenoid valve in the icemaker and a control low-pressure switch in the condensing unit to control the operation of the Comp and FMR. -
Page 13: D) Drain Cycle
d) Drain Cycle (1) 1-in-1 Drain Cycle: DV energizes for 2 seconds once every hour when the 1-in-1 drain cycle is activated (S1 dip switch 4 in the off position (factory default position)). 1-hour drain cycle timer terminates, 2-second DT starts. DV energizes for 2 seconds. -
Page 14: E) Shutdown Cycle
1, 2, 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.3.b) Infrared Sensor Shutdown Delay (S1 dip switch 1, 2, 3)." Once IS shutdown delay timer terminates, CR (X1 on CB) and PDS de-energize and the 5-minute ice purge timer begins. Unit is in pump-down mode. -
Page 15: Sequence Flow Chart
2. Sequence Flow Chart... -
Page 16: Control Board
C. Control Board • A Hoshizaki exclusive control board is employed in Hoshizaki Modular Flakers. • All models are pre-tested and factory set. 1. The control board is fragile; handle very carefully. 2. The control board contains integrated circuits, which are susceptible to failure due to static discharge. -
Page 17: Control Board Layout
1. Control Board Layout • "GM" LED • "COMP" LED (X2 Relay) (X1 Relay) Gear Motor Pump-Down Solenoid Valve Evaporator Heater • K1 Connector (115VAC) #3 115VAC Input #2 Gear Motor, Evaporator Heater • "FLUSH" LED (X3 Relay) Drain Valve • K2 Connector (24VAC) #10 Drain Valve #9 Transformer... -
Page 18: Led Lights And Audible Alarm Safeties
2. LED Lights and Audible Alarm Safeties 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 Fill Cycle WTRIN Ice Purge Cycle Freeze Cycle (with refill) GM, COMP, WTRIN* (refill), 1-in-1 Drain Cycle FLUSH (Drain) (S1 dip switch 4 off) GM, COMP (only if IS not satisfied) 1-in-12 Drain Cycle FLUSH (Drain) DV... -
Page 19: Controls And Adjustments
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. Increasing the shutdown delay allows a higher level of ice in the dispensing unit/storage bin before shutdown. -
Page 20: C) Drain Frequency Control (S1 Dip Switch 4)
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-12 drain cycle is available. S1 Dip Switch Setting OFF (1-in-1) ON (1-in-12) d) Continuous Dispensing Timer (S1 dip switch 5 &... -
Page 21: F) Mechanical Bin Control Shutdown Delay (S1 Dip Switch 8)
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. g) Factory Use (S1 Dip Switch 9 &... -
Page 22: Technical Information
III. Technical Information A. Water Circuit and Refrigeration Circuit 1. FS-1022MLH-C with SRC-10H... -
Page 23: Wiring Diagrams
B. Wiring Diagrams 1. FS-1022MLH-C... -
Page 24: Src-10H
2. SRC-10H * Control Low-Pressure Switch Cut-in 29± PSIG Differential 20± PSIG Cut-out 9 PSIG ** Safety Low-Pressure Switch (Manual Reset) Cut-out 3±2.5 PSIG Differential 6 PSIG *** High-Pressure Switch Cut-out 384± PSIG Cut-in 284±22 PSIG... -
Page 25: Performance Data
C. Performance Data 1. FS-1022MLH-C with SRC-10H APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./DAY ( l/day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. gal. / day (l/day) EVAPORATOR OUTLET TEMP. F ( C) HEAD PRESSURE PSIG (kg/sq.cmG) SUCTION PRESSURE PSIG (kg/sq.cmG) HEAT OF REJECTION FROM BODY... -
Page 26: Service Diagnosis
IV. Service Diagnosis 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Risk of electric shock. Use extreme caution and exercise safe electrical practices. - Page 27 K8 connector pin #1 white/red (W/R) to pin #2 light blue (LBU). If 24VAC is not present and 1A 24VAC fuse is good, replace the control transformer. If 24VAC is present and "POWER OK" LED is off, CB is bad and must be replaced. IS Diagnosis: Check that IS green LED is on. If "POWER OK" LED is on and IS green LED is off, check 20VDC at CB K6 connector brown (BR) wire to dark blue (DBU) wire. If 20VDC is not present, confirm S1 dip switch 7 is in the "ON" position. If S1 dip switch 7 is in the "ON" position and 20VDC is not present, CB is bad and must be replaced. If IS yellow LED is on or flashing, move ice away from IS lens. If no ice is present, clean...
- Page 28 8) Freeze Cycle – "GM" and "COMP" LEDs are on. "GM" LED, GMR (X2 on CB), GM, GMPR, and EH continue. "COMP" LED turns on and PDS energizes. Once the refrigeration circuit low-side pressure rises to 29 PSIG, CLPS closes, energizing MC, which energizes Comp and FMR. Ice production begins 4 to 6 minutes after Comp and FMR energize depending on ambient and water conditions. FS Diagnosis: Check that "COMP" LED is on and that PDS energizes. If "COMP" LED is off, check DC voltage across GMPR terminals 3 and 5 white/orange (W/O) wires.
- Page 29 9) Refill Cycle/Low Water Safety Cycle – "GM", "COMP", and "WTRIN" LEDs are on. As ice is produced, the water level in the reservoir drops. UF/S opens. Nothing happens at this time. When LF/S opens, WV energizes, 90-second low water safety timer (fill timer) starts.
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Page 30: Control Board Check
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. Before proceeding, check for proper voltage per unit nameplate. Check that the 24VAC 1A fuse and the 115VAC 3A GM fuse are good. - Page 31 4) 5VDC Output Checks: Control Switch (open contacts for icemaking, closed contacts for drain), GMPR (terminals 3 & 5), MBC, and F/S. 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.
- Page 32 c. Mechanical Backup Bin Control (MBC) –K8 connector pins #3 and #4 gray (GY) wires: When MBC 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.
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Page 33: Bin Control Check
D. Bin Control Check 1. Infrared Sensor Check 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 backup bin control. 1) Remove the front panel. 2) Move the power switch to the "OFF" position, then unplug the unit from the electrical outlet. 3) Remove the control box cover and access CB. Confirm that S1 dip switch 1, 2, 3 are in the proper position for your application. See "II.C.3.b) Infrared Sensor Shutdown Delay (S1 dip switch 1, 2, 3)."... -
Page 34: Mechanical Backup Bin Control Check
MBC is used as a stand-alone bin control. The stand-alone application should only be used in Hoshizaki standard ice storage bin applications. WARNING! Do not place S1 dip switch 7 in the "OFF" position on dispenser unit applications. When ice fills the chute and engages the actuator paddle, MBC opens and CB shuts down the icemaker within 10 seconds. - Page 35 6) 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 located on CB to bypass the 5-minute ice purge cycle. WARNING! Risk of electric shock. Care should be taken not to touch live terminals. The "COMP" LED turns 7) Press the actuator paddle located in the top of the chute. S1 dip switch 7 in the "ON" position: Comp and GM de-energizes within 10 seconds and CB sounds a 9-beep alarm.
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Page 36: Float Switch Check And Cleaning
E. Float Switch Check and Cleaning 1. Float Switch Check 1) Remove the front panel, then move the power switch to the "OFF" position. 2) Move the control switch to the "DRAIN" position. 3) Move the power switch to the "ON" position. 4) Allow the water to drain from the evaporator, then move the power switch to the "OFF" position and the control switch to the "ICE" position. 5) Unplug the unit from the electrical outlet. 6) Remove the control box cover. 7) Remove CB K8 connector and check F/S continuity. Both the UF/S and LF/S should be open. - Page 37 3) Wipe down F/S assembly with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Rinse the assembly thoroughly with clean water. 4) While not necessary, the floats can be removed from the shaft during cleaning. If you remove them, note that the blue float is on top (UF/S) and the white float is on bottom (LF/S). The floats must be installed with the magnets inside them towards the top of the switch. See Fig. 6. Installing the floats upside down will affect the timing of F/S operation. 5) Rinse the float switch assembly thoroughly with clean water and replace in its correct position. 6) Plug the unit into the electrical outlet, then move the power switch to the "ON" position to start the automatic icemaking process. 7) Replace the front panel in its correct position. Legend: CB–control board; F/S–float switch; GM–gear motor; LF/S–lower float switch; UF/S–upper float switch...
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Page 38: Diagnostic Charts
F. Diagnostic Charts Before consulting the diagnostic charts, check for correct installation, proper voltage per unit nameplate, and adequate water supply. Check CB using the steps in "IV.C. Control Board Check." Check that the S1 dip switch settings are in the factory default position. For factory default settings, see "II.C.3.a) Default Dip Switch Settings." 1. No Ice Production No Ice Production - Possible Cause 1a. Power Supply-FS 1b. Power Supply-SRC 2. Water Supply 3. Power Switch 4. - Page 39 No Ice Production - Possible Cause 3. Gear Motor Protect Relay 1. Gear Motor Protect Relay 2. Control Board 3. Pump-Down Solenoid Valve 4. Magnetic Contactor 5. Control Low-Pressure Switch 6. Safety Low-Pressure Switch (manual reset) 7. High-Pressure Switch 8. Condensing Unit Fan Motor 9.
- Page 40 No Ice Production - Possible Cause 4. Control Board 1. Infrared Sensor Bin Control 2. Mechanical Backup Bin Control 3. Pump-Down Solenoid Valve 4. Control Low-Pressure Switch 5. Magnetic Contactor 6. Control Board a) No power to float switch or not reading float switch condition. b) No power to inlet water valve. Shutdown a) Dirty lens.
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Page 41: Removal And Replacement Of Components
V. Removal and Replacement of Components 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Move the power switch to the "OFF" position and unplug the icemaker from the electrical outlet and turn off the power supply to the condensing unit before servicing. -
Page 42: Refrigerant Recovery
1. Refrigerant Recovery The icemaker unit is provided with refrigerant service valves. Using proper refrigerant practices, recover the refrigerant from the service valves and store it in an approved container. Do not discharge the refrigerant into the atmosphere. 2. Brazing 1. R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). -
Page 43: Important Notes For Component Replacement
Remember to loosen the connection and purge the air from the hose. See the rating label inside the icemaker for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used. -
Page 44: Evaporator Assembly
Upper Bearing (pressed into auger) Seal Bolts and Washers Socket Head Cap Screw and Split Lock Washer Truss Head Screw w/Rubber Washer Gear Motor Barrier Gear Motor Fig. 7 Evaporator Assembly Evaporator Heater Cutter Hex Head Bolt Cutter Washer Extruding Head Dowel Pin Auger O Ring... -
Page 45: Upper Bearing Wear Check
1. Upper Bearing Wear Check To ensure that the bearing inside the extruding head does not exceed the wear tolerance of .02", follow the instructions below. 1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the unit from the electrical outlet. 2) Remove the top and side 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 and washer. -
Page 46: Removal And Replacement Of Extruding Head
8) Plug the unit into the electrical outlet, then move the power switch to the "ON" position to start the automatic icemaking process. 9) Replace the front panel in its correct position. 3. Removal and Replacement of Extruding Head 1) Remove the front panel, then move the power switch to the "OFF" position. 2) Move the control switch to the "DRAIN" position. 3) Move the power switch to the "ON" position. 4) Allow the water to drain from the evaporator. 5) Move the power switch to the "OFF" position, then unplug the unit from the electrical outlet. 6) Remove the top and side panels. 7) Remove the strap connecting the spout to the chute assembly, then remove the spout. -
Page 47: Removal And Replacement Of Evaporator
13) Move the control switch to the "ICE" position. 14) Plug the unit into the electrical outlet, then move the power switch to the "ON" position to start the automatic icemaking process. 15) Replace the front panel in its correct position. 5. Removal and Replacement of Evaporator 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made. -
Page 48: Removal And Replacement Of Mechanical Seal And Lower Housing
20) Evacuate the system, and charge it with refrigerant. See the rating label inside the icemaker for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used. -
Page 49: Removal And Replacement Of Gear Motor
12) Remove the O-ring and mechanical seal from the housing. If only replacing the mechanical seal, proceed to step 15. To help prevent water leaks, be careful not to damage the surfaces of the O-ring or mechanical seal. 6b. Lower Housing 13) Remove the hex bolts w/washers securing the lower housing to the gear motor and remove the lower housing from the gear motor. - Page 50 11) Remove the gear motor bracket and spline coupling from the old gear motor and place on the new gear motor. 12) Install the new gear motor and reconnect the electrical wires. 13) Replace the removed parts in the reverse order of which they were removed. 14) Replace the top and side panels in their correct positions.
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Page 51: Cleaning And Maintenance
3. The dispenser unit/storage bin is for ice use only. Do not store anything else in 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. - Page 52 5) Remove all of the ice from the dispenser unit/storage bin. 6) Remove the strap connecting the spout to the chute assembly, then remove the spout. See Fig. 9. Proximity Switch Backup Bin Control Assembly Mount Ties (Hook and Loop) Chute Insulation Fig.
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Page 53: Sanitizing Solution
11) Wipe down the infrared sensor lens, (located on the bottom of the icemaker) with the cleaning solution. Next, rinse the cleaning solution off of the infrared sensor lens with a clean, damp cloth. 12) Replace the top panel in its correct position. Move the control switch to the "ICE" position, then plug the unit back in. Move the power switch to the "ON" position, then replace the front panel in its correct position. Make ice using the solution until the icemaker stops making ice. -
Page 54: Sanitizing Procedure - Final
3) Pour the sanitizing solution over the extruding head until the evaporator assembly and the reservoir are full and the solution starts to overflow into the drain pan. 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. -
Page 55: Maintenance
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 1-800-233-1940 in the USA. 1. Only qualified service technicians should attempt to service this icemaker. - Page 56 Frequency Area Monthly External Water Filters Icemaker and Dispenser Unit/ Storage Bin Exterior Infrared Sensor Lens; Underside of Icemaker and Top Kits; Bin Door and Snout (if applicable) Every 6 Icemaker and Months Dispenser Unit/ Storage Bin Evaporator Condensate Drain Pan and Gear Motor Drain Pan Icemaker and...
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Page 57: Preparing The Icemaker For Long Storage
C. Preparing the Icemaker for Long Storage When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. When the icemaker is not used for two or three days under normal conditions, it is sufficient to only move the power switch to the "OFF" position. When storing the icemaker for extended time or in sub-freezing temperatures, follow the instructions below.