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Hoshizaki TM-500AAE Service Manual

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THIN GLASS ICE MAKER
MODEL
SERVICE MANUAL
HOSHIZAKI
TM-500AAE
NO.
E2TA-684
ISSUED:
SEP. 23, 2005
REVISED: JUN. 26, 2007

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Summary of Contents for Hoshizaki TM-500AAE

  • Page 1 E2TA-684 ISSUED: SEP. 23, 2005 REVISED: JUN. 26, 2007 HOSHIZAKI THIN GLASS ICE MAKER TM-500AAE MODEL SERVICE MANUAL...

  • Page 2: Table Of Contents

    CONTENTS PAGE I. SPECIFICATIONS ------------------------------------------------------------------------------------- 1 1. FEATURES ---------------------------------------------------------------------------------------- 1 [a] FLOOR MOUNTING AND FIXED MOUNTING ---------------------------------------- 1 [b] BIN CONTROL ADJUSTMENT (Fixed Mounting Only) ------------------------------ 1 [c] ICE PRODUCTION CONTROL (Fan Control) ------------------------------------------ 1 [d] OVERLOAD PROTECTION --------------------------------------------------------------- 1 [e] USER RESET --------------------------------------------------------------------------------- 1 [f] ERROR CODES AND RECORDS ------------------------------------------------------- 1 [g] OTHER INFORMATION --------------------------------------------------------------------- 2...
  • Page 3 [a] INDICATION ---------------------------------------------------------------------------------- 37 [b] PROTECTORS ------------------------------------------------------------------------------ 37 9. ERROR CODES --------------------------------------------------------------------------------- 39 10. PERFORMANCE DATA ---------------------------------------------------------------------- 41 [a] TM-500AAE (Thick Ice) -------------------------------------------------------------------- 41 [b] TM-500AAE (Thin Ice) ---------------------------------------------------------------------- 42 IV. SERVICE DIAGNOSIS ---------------------------------------------------------------------------- 43 1. NO ICE PRODUCTION ------------------------------------------------------------------------- 43 2.
  • Page 4 8. FLUSH WATER VALVE ----------------------------------------------------------------------- 59 9. CONTROLLER BOARD ----------------------------------------------------------------------- 60 10. LINE VALVE -------------------------------------------------------------------------------------- 60...

  • Page 5: Specifications

    I. SPECIFICATIONS 1. FEATURES [a] FLOOR MOUNTING OR FIXED MOUNTING The floor mounting and fixed mounting options are available. Use the rotary Select Switch provided on top of the Operation Panel to choose between the two options. If the fixed mounting option is selected, the Bin Control Switch in the Control Box will become functional.

  • Page 6: [G] Other Information

    [g] OTHER INFORMATION Other information is also available from the Controller Board. See "III. 7. OPERATION BOARD" for details. [h] CHANGE OF ICE TYPE The ice type is changeable by replacing the Pulleys provided on the Gear Motor and Gear Head driving the Evaporator (Drum).

  • Page 7: Dimensions/Connections

    2. DIMENSIONS/CONNECTIONS...

  • Page 8: Specifications

    3. SPECIFICATIONS AC SUPPLY VOLTAGE 1 PHASE 230V 50Hz AMPERAGE 10.3A (Ambient temp. 32°C, Water temp. 21°C) STARTING AMPERAGE 75.9A ELECTRIC CONSUMPTION 2035W (Ambient temp. 32°C, Water temp. 21°C) POWER FACTOR 85.6% POWER SUPPLY CAPACITY Min 4.8kVA (20.9A) ICE PRODUCTION PER 24h Thick Ice Thin Ice Approx.

  • Page 9: Construction

    4. CONSTRUCTION Float Switch Control Water Valve Top View Icemaking Unit Control Box - Operation Flush Water Valve Fan Motor Line Valve Control Box - Main Compressor Pressure Switch Front View Gear Motor Expansion Valve Receiver Tank Drier Left Side View Right Side View...

  • Page 10: Maintenance And Cleaning Instructions

    II. MAINTENANCE AND CLEANING INSTRUCTIONS IMPORTANT This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. 1. TIMING BELT The Timing Belt transmits power from the Gear Motor to the Gear Head. It may wear or deteriorate and break after a total of 15,000 hours of Gear Motor operation.

  • Page 11: 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 12: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT Pressure Switch Low Side Cut-out 0.03 ± 0.02 MPa Cut-in 0.1 ± 0.02 MPa High Side Cut-out 3.2 ± 0.02 MPa Cut-in 2.55 ± 0.02 MPa...

  • Page 13: Wiring Diagram

    2. WIRING DIAGRAM [a] WIRING DIAGRAM...

  • Page 14: [B] Control Box Layout

    [b] CONTROL BOX LAYOUT...

  • Page 15: Icemaking Mechanism

    3. ICEMAKING MECHANISM [a] EVAPORATOR (DRUM) The Evaporator consists of an aluminum alloy cylinder with an icemaking surface on its exterior, a press-fit plastic part with a refrigerant path, and a shaft for refrigerant supply and rotation. The Evaporator penetrates the side of the Tank, and the Cutter scrapes off ice forming on the Evaporator surface.

  • Page 16: [E] Heater (Cutter)

    [e] HEATER (CUTTER) The Heater provided on the backside of the Cutter prevents ice jamming on the Cutter resulting in a clogged Spout and ice forming on the back of the Cutter at a low temperature. The thermal sensor attached on the water inlet controls to energize the Heater. [f] HEATER (TANK) The Heater provided inside the Tank prevents the Float Switch from freezing.

  • Page 17: [C] Flush Water Valve

    [c] FLUSH WATER VALVE The Flush Water Valve is energized to open and flush out the Tank (100V AC) after the icemaker shuts down and every 12 hours when the Storage Bin is used. [d] DRAINING ICEMAKER IN SUBFREEZING CONDITIONS In winter, the water circuit must be completely drained out or otherwise protected to prevent freeze-up and damage before shutting down the icemaker at night.

  • Page 18: Refrigeration Circuit

    5. REFRIGERATION CIRCUIT [a] APPLICABLE PARTS Refrigerant (R404A) Compressor Evaporator Tank Air-cooled Condenser Air-cooled Condenser Fan Motor (1 pc) Drier Solenoid Valve Strainer Thermal Expansion Valve Access Valve Heat Exchanger [b] SERVICE INSTRUCTIONS Always restore the original bindings after servicing the refrigeration circuit. Otherwise, vibration may cause overstress and damage to the circuit, resulting in refrigerant leak.

  • Page 19: [F] Compressor

    to an open flame, R404A creates Phosgene gas, hazardous in large amounts. Handle the refrigerant in a well-ventilated area with no flames. Always recover the refrigerant and store it in a proper container, if required by an applicable law. Do not discharge the refrigerant into the atmosphere. [f] COMPRESSOR The Compressor absorbs the low-pressure refrigerant gas vaporized in the Evaporator (to reduce the pressure inside the Evaporator), compresses the refrigerant into high-temperature high-...

  • Page 20: [I] Condenser Cooling Fan Motor

    [i] CONDENSER COOLING FAN MOTOR The Fan Motor cools the Air-cooled Condenser and sends air to condense refrigerant gas inside the Condenser. [j] DRIER The Drier uses desiccants (molecular sieves + activated alumina) to absorb moisture in the refrigeration circuit. The built-in filter also corrects foreign matter in the refrigeration circuit to prevent troubles with valves clogged with dirt or moisture.

  • Page 21: 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 turned ON and the Ice Button is pressed (floor mounting) or in 30 seconds after the Bin Control Switch checks that the Storage Bin is not filled with ice (fixed mounting).

  • Page 22: [B] Timing Chart (Floor Mounting)

    [b] TIMING CHART (Floor Mounting)

  • Page 23: [C] Timing Chart (Fixed Mounting)

    [c] TIMING CHART (Fixed Mounting)

  • Page 24: [D] Sequence

    [d] SEQUENCE (1) Startup - Water Supply [Floor Mounting]...
  • Page 25 (1) Startup - Water Supply [Fixed Mounting]...
  • Page 26 (2) Startup - After completion of water supply, Fan Motor and Line Valve start in 2 min [Floor Mounting]...
  • Page 27 (2) Startup - After completion of water supply, Fan Motor and Line Valve start in 2 min [Fixed Mounting]...
  • Page 28 (3) Startup - After Fan Motor and Line Valve start, Compressor starts in 15 sec [Floor Mounting]...
  • Page 29 (3) Startup - After Fan Motor and Line Valve start, Compressor starts in 15 sec [Fixed Mounting]...
  • Page 30 (4) Startup - Ice production starts [Floor Mounting]...
  • Page 31 (4) Startup - Ice production starts [Fixed Mounting]...
  • Page 32 (5) Normal Operation - Bin control and drain cycle (480 sec) start [Fixed Mounting]...
  • Page 33 (6) Shutdown - After pump down and drain cycle (480 sec) start, Compressor stops in 5 sec [Floor Mounting]...
  • Page 34 (6) Shutdown - After pump down and drain cycle (480 sec) start, Compressor stops in 5 sec [Fixed Mounting]...
  • Page 35 (7) Shutdown - Drain [Floor Mounting]...
  • Page 36 (7) Shutdown - Drain [Fixed Mounting]...

  • Page 37: [E] Operation Board

    [e] OPERATION BOARD The Operation Board is provided for operation of the icemaker. See “7. OPERATION BOARD” for details. [f] CONTROLLER BOARD The icemaker is controlled by the Controller Board based on the following logic: 1) Ice Production Control In a low ambient or water temperature condition, the ice production capacity will increase. Then, the Gear Motor will have a larger torque to scrape off ice, which will overload the entire icemaking mechanism.

  • Page 38: [H] Bin Control Switch (Fixed Mounting Only)

    caused by internal and external noises. [h] BIN CONTROL SWITCH (Fixed Mounting Only) The Bin Control Switch is located in the Control Box - Main (see “2. [b] CONTROL BOX LAYOUT”). The Bin Control Switch employs a photoelectric sensor to measure the depth by reflected orange LED light.

  • Page 39: Operation Board

    7. OPERATION BOARD Visible from Window Panel [a] USER OPERATION (accessible from the Window Panel) Symbol Button Functions Floor Mounting: When pressed during shutdown, the unit will be supplied with water and start icemaking operation. When pressed in STOP mode, the unit will start icemaking operation. Fixed Mounting: When pressed during shutdown, the unit will be supplied with water.

  • Page 40: [B] Service Operation

    [b] SERVICE OPERATION (Remove the Front Panel for access to the service buttons) CAUTION Removal of the Front Panel will expose moving and hot parts. It is allowed for qualified service personnel only. Symbol Button Symbol Button Option Floor Mounting Drum Rotation Fixed Mounting 1) Drum Rotation Button...

  • Page 41: Protectors

    8. PROTECTORS [a] INDICATION When an error occurs, “E_” or ”c_” will appear in the Display Window. When an operational error occurs, “E_” or “C_” will appear and blink in the Display Window on the Operation Board, and the icemaker will stop. When a service call is received, ask the user to check which error code is in the Display Window.
  • Page 42 2) Gear Motor Thermal Protector Provided on the motor coil. Operates when the motor temperature rises. The protector is auto-reset, but the controller shuts down the icemaker. Press the Reset Button to restart. Photomicrosensor Counts the number of drum rotation and in case of abnormality, shuts down the icemaker including the Gear Motor.

  • Page 43: Error Codes

    minutes while the Compressor is running, and stops icemaking operation. “E1” will appear in the Display Window. 9) Thermistor The code “EA” (Water Temperature Thermistor) or “Eb” (Condenser Center Thermistor) will blink in the Display Window if the Thermistor circuit detects infinite resistance (open circuit or bad contact).
  • Page 44 Code Error Condition Operation Reset Check/Repair Condenser Condenser temperature Fan control Press Center Condenser Center stays below -50°C for 1 stays at full Reset Thermistor Thermistor second. speed. Button. Circuit Open Refrigeration circuit, While pumping down Press Installation Low Pressure refrigeration system, Low EC blinks.

  • Page 45: Performance Data

    10. PERFORMANCE DATA [a] TM-500AAE (Thick Ice)

  • Page 46: [B] Tm-500Aae (Thin Ice)

    [b] TM-500AAE (Thin Ice)

  • Page 47: Service Diagnosis

    IV. SERVICE DIAGNOSIS Display error record by operating the Operation Board (See “III. 7. [b] 2) Displaying Error Record”). 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 48: Low Ice Production

    PROBLEM POSSIBLE CAUSE REMEDY [3] (Continued) b) Controller Board 1. Broken. 1. Replace. c) 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 49: Others

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

  • Page 50: Removal And Replacement Of Components

    V. REMOVAL AND REPLACEMENT OF COMPONENTS 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 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 51: [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 52: Brazing

    7) Turn on the icemaker. Release the High-side Access Connector, and allow pressure in the charging line to slowly enter the low side of the system. Cap off the High-side Access Valve. When pressure reduces on the low side, disconnect the low side charging line and cap off the Access Valve.

  • Page 53: Compressor

    3. 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) Disconnect the power source. 2) Remove the panels. 3) Remove the Terminal Cover on the Compressor, and disconnect the Compressor wiring.

  • Page 54: Drier

    15) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required refrigerant charge (See “1. [c] EVACUATION AND RECHARGE”). 16) Connect the Terminals to the Compressor, and replace the Terminal Cover in its correct position. 17) Refit the panels in their correct position. 18) Connect the power source.

  • Page 55: Expansion Valve

    5. 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 repair or replacement has been made.

  • Page 56: Evaporator Assembly

    6. EVAPORATOR ASSEMBLY 1) Push the Stop Button to drain the water in the Tank. 2) Disconnect the power source. 3) Remove the panels. 4) Unscrew and remove the following parts (see Fig. 1 - 3): Tank Guide Spout Switch Tank Cover (C) Tank Cover (A) with Heater (Tank) To completely disconnect it from the unit, loosen the closed end connector or cut the...
  • Page 57 Fig. 1 Fig. 2 Fig. 3...
  • Page 58 CUTTER (Fig. 4, 5) 8) Remove the Heater Holder (L). 9) Loosen the screws, and remove the Support - Cutter and Cutter. The Cutter is attached with the Heater and Thermal Fuse. To completely disconnect it from the unit, loosen the closed end connector or cut the wire.
  • Page 59 HOUSING AND MECHANICAL SEAL (Fig. 6) 13) Remove the two Insulations and the seven screws securing the entire Housing assembly. 14) Remove the Mechanical Seal, C-ring and Gasket. Note: Do not damage the Shaft. Use a special tool to remove the C-ring. 15) Slowly loosen the two temporary screws on the Housing (B).
  • Page 60 TANK (Fig. 7) 18) Remove the four Joint Shafts and the Tank Brackets to take off the Tanks (L), (R) and (LO). 19) Remove the Side Boss (L) and Bearing from the Tank (L). 20) Remove the Side Boss (R), Mounts - Gear and Gear Head from the Tank (R). Note: Be careful not to lose the O-rings in steps 19) and 20).
  • Page 61 30) Install the Oil Seals in the proper directions. 31) When fitting the Mechanical Seals, use a clean smooth cloth containing MEK or acetone to lightly wipe off the anti-rust oil, and apply a refrigeration oil (Copeland CS20 ester oil) to the mating surfaces, rubber parts and Shaft.

  • Page 62: Control Water Valve

    36) After filling the oil, turn the Drum about twenty times to smooth the mating surfaces of the Mechanical Seals. Then, run a pressure resistance test at 1.5 - 2.0MPa to check for leaks. 37) When replacing the Ice Guide - Side, attach the Label - PE on the contact surfaces of the Tanks (L) and (R) for material identification.

  • Page 63: Flush Water Valve

    8) Assemble the removed parts in the reverse order of which they were removed. 9) Open the water supply tap. 10) Connect the power source. 11) Check for water leaks. 12) Refit the panels in their correct position. 8. FLUSH WATER VALVE 1) Close the water supply tap.

  • Page 64: Controller Board

    17) Refit the panels in their correct position. 9. CONTROLLER BOARD IMPORTANT A single type Controller Board is supplied as a Service Board. Do not repair any parts and electronic devices on the Controller Board in the field. Replace the whole board with a new Service Board. 1) Disconnect the power source.
  • Page 65 4) Remove the Line Valve using brazing equipment. 5) Disconnect the coil from the new Line Valve. 6) Braze the new Line 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.

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