Hoshizaki FD-1001MAH Service Manual Download Page 65

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Drain Valve
#10 (white/blue)

•

K6 Connector (20VDC)

Infrared Sensor

•

"SERVICE" Button

(Ice Purge Cycle Bypass)

Transformer
24VAC Input
#1 (white/red)

Upper Float Switch
#6 (red)
Open-5VDC to #5 black
Closed-0VDC to #5 black

Mechanical Bin Control
#3 to #4 (gray)
Open-5VDC
Closed-0VDC

Gear Motor Protect Relay Circuit
#5 to #6 (white/orange)
Relay De-Energized-Open-5VDC
Relay Energized-Closed-0VDC

High Pressure Switch
#3 to #4 (yellow)
Open-5VDC
Closed-0VDC

Control Switch
#1 to #2 (white/black)
"ICE"-Open-5VDC
"DRAIN"-Closed-0VDC

•

"POWER OK" LED

Transformer
24VAC Neutral
#2 (light blue)

Lower Float Switch
#7 (dark blue)
Open-5VDC to #5 black
Closed-0VDC to #5 black

Float Switch
#5 (black)

•

S1 Dip Switch

•

K9 Connector

•

K8 Connector

(24VAC and 5VDC)

•

K7 Connector

-open

•

K2 Connector

(24VAC)

Fig. 6

Open
(yellow LED flashing
or steady)
20VDC DBU to BR
0VDC DBU to W
20VDC W to BR

Closed
(yellow LED off)
20VDC DBU to BR
20VDC DBU to W
0VDC W to BR

Brown
(BR)

Dark Blue
(DBU)

White
(W)

5VDC common terminals

•

K1 Connector

(115VAC)

#3 Input (black)
#2 GM, FMR,
FMS (brown)

Inlet Water Valve
#8 (white/brown)

Transformer
Input
#9 (white/red)

Transformer
Input
#7 (white/red)

Summary of Contents for FD-1001MAH

Page 1: ...oshizaki A Superior Degree of Reliability www hoshizaki com Models FD 1001MAH C FD 1001MWH C FD 1001MRH C FD 1001MLH C Modular Flaker Hoshizaki America Inc Number 73159 Issued 2 12 2010 SERVICE MANUAL...

Page 2: ...er 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 assistanc...

Page 3: ...D 1001MRH C remote air cooled 13 7 FD 1001MLH low side parallel rack system 14 8 FD 1001MLH C low side parallel rack system 15 B Condenser Unit 16 1 URC 5F 16 II General Information 18 A Construction...

Page 4: ...34 E Float Switch 34 III Technical Information 35 A Water Circuit and Refrigeration Circuit 35 1 FD 1001MAH C air cooled 35 2 FD 1001MWH C water cooled 36 3 FD 1001MRH C remote air cooled 37 4 FD 1001...

Page 5: ...cement of Cutter 82 3 Removal and Replacement of Extruding Head 83 4 Removal and Replacement of Auger 83 5 Removal and Replacement of Evaporator 84 6 Removal and Replacement of Mechanical Seal and Low...

Page 6: ...aning and Sanitizing Instructions 96 1 Cleaning Solution 96 2 Cleaning Procedure 96 3 Sanitizing Solution 98 4 Sanitizing Procedure Initial 98 5 Sanitizing Procedure Final 99 B Maintenance 100 C Prepa...

Page 7: ...ock serious injury or fire follow basic precautions including the following Electrical connection must be hard wired and must meet national state and local electrical code requirements Failure to meet...

Page 8: ...8 I Specifications A Icemaker 1 FD 1001MAH air cooled Awaiting Data Note We reserve the right to make changes in specifications and design without prior notice...

Page 9: ...658mm EXTERIOR FINISH Stainless Steel Galvanized Steel Rear WEIGHT Net 176 lbs 80 kg Shipping 205 lbs 93 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT IC...

Page 10: ...10 3 FD 1001MWH water cooled Note We reserve the right to make changes in specifications and design without prior notice Awaiting Data...

Page 11: ...11 Note We reserve the right to make changes in specifications and design without prior notice 4 FD 1001MWH C water cooled Awaiting Data...

Page 12: ...12 Note We reserve the right to make changes in specifications and design without prior notice 5 FD 1001MRH remote air cooled Awaiting Data...

Page 13: ...TER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT REFRIGERATION Discharge line 1 1 16 12 UNF Fitting 10 AEROQUIP CIRCUIT Liquid line 5 8 18 UNF Fitting 6 AEROQUIP ICE MAKING SYSTEM Auger type HARVESTING S...

Page 14: ...14 7 FD 1001MLH low side parallel rack system Awaiting Data Note We reserve the right to make changes in specifications and design without prior notice...

Page 15: ...15 8 FD 1001MLH C low side parallel rack system Awaiting Data Note We reserve the right to make changes in specifications and design without prior notice...

Page 16: ...arge Line 1 1 16 12 UNF Fitting 10 AEROQUIP Liquid Line 5 8 18 UNF Fitting 6 AEROQUIP CONDENSER Air cooled Fin and tube type FAN MOTOR PROTECTION Thermal Protection REFRIGERANT CONTROL Condensing Pres...

Page 17: ...0 mm 20 15 32 520 mm 21 15 16 557 mm 7 8 DIA HOLE 23 mm DIA 6 5 16 160 mm 2 15 16 75 mm 18 1 8 460 mm 6 16 3 4 10 20 mm 4 2 SLOTTED HOLES 17 1 8 435 mm 14 9 16 370 mm 14 1 8 358 mm 14 15 16 380 mm 15...

Page 18: ...ruction 1 FD 1001MAH C air cooled Inlet Water Valve Expansion Valve Control Box Air Cooled Condenser Mechanical Bin Control Spout Evaporator Gear Motor Compressor Fan Motor Ice Chute Infrared Sensor E...

Page 19: ...cooled Inlet Water Valve Expansion Valve Control Box Water Cooled Condenser Mechanical Bin Control Spout Evaporator Gear Motor Compressor Water Regulating Valve Ice Chute Infrared Sensor Extruding He...

Page 20: ...3 FD 1001MRH C remote air cooled Inlet Water Valve Expansion Valve Control Box Mechanical Bin Control Spout Evaporator Gear Motor Compressor Ice Chute Infrared Sensor Extruding Head Heater FD 1001MRH...

Page 21: ...system Inlet Water Valve Expansion Valve Control Box Mechanical Bin Control Spout Evaporator Gear Motor Ice Chute Evaporator Pressure Regulator Suction Line Valve Liquid Line Valve Strainer Infrared S...

Page 22: ...Extruding Head Upper Bearing Extruding Head Heater Cubelet Models Only Auger Cylinder Mechanical Seal O Ring Housing Lower Bearing Spline Coupling Gear Motor Hexagon Head Bolt Insulation Allen Head Ca...

Page 23: ...ze LLV and SLV energize on MLH models As water in the evaporator cools ice starts forming within 4 to 6 minutes This time frame depends on the inlet water and ambient temperature conditions UF S and L...

Page 24: ...flashing or steady IS shutdown delay timer S1 dip switch 1 2 3 begins For a typical dispenser unit application a 100 second shutdown delay is recommended When used with a standard Hoshizaki storage bi...

Page 25: ...or steady IS delay determined by S1 dip switch 1 2 3 4 Icemaker Restart 5 minutes Note If IS fails to shutdown the icemaker MBC opens and a 9 beep alarm sounds 4 Icemaker Restart 2 Ice Purge Cycle 3 1...

Page 26: ...rt of the icemaker before handling or replacing the control board 3 Do not touch the electronic devices on the control board or the back of the control board to prevent damage to the control board 4 D...

Page 27: ...Mechanical Bin Control 3 4 gray 5VDC Gear Motor Protect Relay Circuit 5 6 white orange High Pressure Switch 3 4 yellow Control Switch 1 2 white black Inlet Water Valve 8 white brown POWER OK LED Trans...

Page 28: ...ergizes for 2 seconds This occurs once every hour when the 1 in 1 drain cycle is activated S1 dip switch 4 in the OFF position factory default This setting is recommended for optimum icemaker performa...

Page 29: ...er Safety UF S open 90 seconds after WV energized Automatic reset once water supply is restored and UF S closes 2 Control Switch In DRAIN position longer than 15 minutes Automatic reset once the contr...

Page 30: ...ker automatically starts running again 2 4 beep alarm For the third high pressure switch activation in 1 hour the icemaker shuts down and the control board sounds a 4 beep alarm every 5 seconds This a...

Page 31: ...motor protect relay energizes For further details see IV B Diagnostic Procedure h Bin Control 9 beep alarm This alarm provides protection to prevent the icemaker from overfilling the ice storage bin I...

Page 32: ...No 1 No 2 No 3 OFF OFF OFF 0 Seconds ON OFF OFF 100 Seconds 1 6 minutes Factory Default OFF ON OFF 1100 Seconds 18 3 minutes OFF OFF ON 1650 Seconds 27 5 minutes ON ON OFF 2200 Seconds 36 7 minutes O...

Page 33: ...oat switch closes is 5 seconds WARNING Do not place S1 dip switch 7 in the off position on dispenser unit applications S1 Dip Switch Setting Bin Control Application Gear Motor Delay No 7 OFF Mechanica...

Page 34: ...there is sufficient water in the reservoir during fill and refill The control board monitors the upper float switch to de energize the inlet water valve when the upper float switch closes during fill...

Page 35: ...d Drier Condenser Condenser Fan Motor Access Valve Pressure Switch Access Valve Compressor Water Circuit Refrigerant Circuit Overflow Reservoir Gear Motor Drain Valve Expansion Valve Spout Water Level...

Page 36: ...s Valve Compressor Water Circuit Refrigerant Circuit Overflow Reservoir Gear Motor Drain Valve Expansion Valve Spout Water Level Evaporator Float Switch Inlet Water Valve Water Supply Line Drain Pan D...

Page 37: ...essor Water Circuit Refrigerant Circuit Overflow Reservoir Gear Motor Drain Valve Expansion Valve Spout Water Level Evaporator Float Switch Inlet Water Valve Water Supply Line Drain Pan Drain Outlet I...

Page 38: ...Water Circuit Refrigerant Circuit Overflow Reservoir Gear Motor Drain Valve Expansion Valve Spout Water Level Evaporator Float Switch Inlet Water Valve Water Supply Line Drain Pan Drain Outlet Insula...

Page 39: ...L BOARD S1 SERVICE BUTTON S2 DIP SWITCH X1 COMPRESSOR RELAY WIRE COLOR CODE R RED BK BLACK BR BROWN O ORANGE Y YELLOW GR GREEN GY GRAY P PINK V VIOLET W WHITE LBU LIGHT BLUE DBY DARK BLUE W BU WHITE B...

Page 40: ...TON S2 DIP SWITCH X1 COMPRESSOR RELAY WIRE COLOR CODE R RED BK BLACK BR BROWN O ORANGE Y YELLOW GR GREEN GY GRAY P PINK V VIOLET W WHITE LBU LIGHT BLUE DBY DARK BLUE W BU WHITE BLUE W R WHITE RED W BK...

Page 41: ...and reservoir fills CONTROL BOARD S1 SERVICE BUTTON S2 DIP SWITCH X1 COMPRESSOR RELAY WIRE COLOR CODE R RED BK BLACK BR BROWN O ORANGE Y YELLOW GR GREEN GY GRAY P PINK V VIOLET W WHITE LBU LIGHT BLUE...

Page 42: ...0 second gear motor delay is active when S1 dip switch 7 is in the on position Otherwise gear motor has a 5 second delay when upper float switch closes CONTROL BOARD S1 SERVICE BUTTON S2 DIP SWITCH X1...

Page 43: ...on line valve on MLH models CONTROL BOARD S1 SERVICE BUTTON S2 DIP SWITCH X1 COMPRESSOR RELAY WIRE COLOR CODE R RED BK BLACK BR BROWN O ORANGE Y YELLOW GR GREEN GY GRAY P PINK V VIOLET W WHITE LBU LIG...

Page 44: ...GREEN GY GRAY P PINK V VIOLET W WHITE LBU LIGHT BLUE DBY DARK BLUE W BU WHITE BLUE W R WHITE RED W BK WHITE BLACK W BR WHITE BROWN W 0 WHITE ORANGE d 1 in 1 Drain Cycle Compressor liquid line valve s...

Page 45: ...tinues 5 minute ice purge timer terminates gear motor de energizes Drain valve opens for 10 minutes CONTROL BOARD S1 SERVICE BUTTON S2 DIP SWITCH X1 COMPRESSOR RELAY WIRE COLOR CODE R RED BK BLACK BR...

Page 46: ...nsor shutdown sequence begins For further information see II B 1 e Shutdown Cycle CONTROL BOARD S1 SERVICE BUTTON S2 DIP SWITCH X1 COMPRESSOR RELAY WIRE COLOR CODE R RED BK BLACK BR BROWN O ORANGE Y Y...

Page 47: ...sounds Dip Switch 7 OFF Hoshizaki ice storage bin applications only The icemaker shuts down within 10 seconds of the mechanical bin control opening CONTROL BOARD S1 SERVICE BUTTON S2 DIP SWITCH X1 CO...

Page 48: ...ns open until the upper float switch closes If this occurs during refill the icemaker cycles down CONTROL BOARD S1 SERVICE BUTTON S2 DIP SWITCH CONTROL X1 COMPRESSOR RELAY WIRE COLOR CODE R RED BK BLA...

Page 49: ...il the high side pressure returns to an acceptable level See II C 3 c High Pressure Switch 3 4 beep alarms CONTROL BOARD S1 SERVICE BUTTON S2 DIP SWITCH CONTROL X1 COMPRESSOR RELAY WIRE COLOR CODE R R...

Page 50: ...50 C Performance Data 1 FD 1001MAH air cooled Awaiting Data Note We reserve the right to make changes in specifications and design without prior notice...

Page 51: ...17 80 304 gal day l day 100 77 292 74 280 70 265 EVAPORATOR OUTLET TEMP 70 17 9 17 9 17 9 80 17 9 14 10 14 10 90 14 10 14 10 12 11 F C 100 12 11 12 11 12 11 HEAD PRESSURE 70 304 21 4 304 21 4 304 21 4...

Page 52: ...52 Note We reserve the right in make changes to specifications and design without prior notice Awaiting Data 3 FD 1001MWH water cooled...

Page 53: ...53 4 FD 1001MWH C water cooled Awaiting Data Note We reserve the right to make changes in specifications and design without prior notice...

Page 54: ...54 5 FD 1001MRH remote air cooled Awaiting Data Note We reserve the right to make changes in specifications and design without prior notice...

Page 55: ...APORATOR OUTLET TEMP 70 5 15 5 15 5 15 80 5 15 9 13 9 13 90 9 13 9 13 12 11 F C 100 12 11 12 11 12 11 HEAD PRESSURE 70 205 14 4 205 14 4 205 14 4 80 234 16 5 234 16 5 234 16 5 90 264 18 6 264 18 6 264...

Page 56: ...56 7 FD 1001MLH low side parallel rack system Awaiting Data Note We reserve the right to make changes in specifications and design without prior notice...

Page 57: ...57 Awaiting Data 8 FD 1001MLH C low side parallel rack system Note We reserve the right to make changes in specifications and design without prior notice...

Page 58: ...iagnostic procedure is a sequence check that allows you to diagnose the electrical system and components Before proceeding check for correct installation adequate water supply minimum of 10 PSIG maxim...

Page 59: ...that the actuator paddle is properly positioned Check for continuity across MBC proximity switch When MBC proximity switch is closed 5VDC is present at CB K8 connector pin 3 or 4 gray GY to CB white K...

Page 60: ...OMP LED is on and Comp is off check for 115VAC at CB X1 Comp relay Comp LLV MLH model and SLV MLH model Check Comp internal overload motor protector start relay and capacitors 9 Refill Cycle Low Water...

Page 61: ...The POWER OK LED turns on Diagnosis POWER OK LED Check that the POWER OK LED is on If not check for proper supply voltage 115VAC input to the control transformer power switch breaker fuse and circuit...

Page 62: ...20VDC Multimeter 5 5VDC control board switch output checks Control Switch High Pressure Switch Gear Motor Protect Relay terminals 3 5 Mechanical Bin Control Proximity Switch and Float Switch When chec...

Page 63: ...present from the K9 connector pin 3 yellow Y wire to K9 connector pin 4 yellow Y wire When the high pressure switch is open 5VDC is present from the K9 connector pin 3 yellow Y wire to K9 connector p...

Page 64: ...oss the inlet water valve solenoid If 24VAC is present turn off the power supply and check continuity across the inlet water valve solenoid If open replace the inlet water valve 7 GM LED is on and the...

Page 65: ...ch 1 to 2 white black ICE Open 5VDC DRAIN Closed 0VDC POWER OK LED Transformer 24VAC Neutral 2 light blue Lower Float Switch 7 dark blue Open 5VDC to 5 black Closed 0VDC to 5 black Float Switch 5 blac...

Page 66: ...press the SERVICE button on the control board to bypass the 5 minute ice purge cycle See II C 1 Control Board Layout WARNING Risk of electric shock Care should be taken not to touch live terminals Th...

Page 67: ...itch 7 placed in the OFF position the mechanical bin control is used as a stand alone bin control The stand alone application should only be used in Hoshizaki standard ice storage bin applications Whe...

Page 68: ...sis If the mechanical bin control fails to open or the icemaker fails to shut down check that the actuator paddle is moving freely Confirm that the actuator paddle is engaged Check for continuity acro...

Page 69: ...the power switch to the OFF position 8 Remove the molex plug from the control box and check continuity across the float switch wires Black BK to red R for the upper float and black BK to blue DBU for...

Page 70: ...Black BK common Dark Blue DBU lower float switch Upper Float blue Magnet towards top Magnet towards top Lower Float white Plastic Retainer Clip Spring Retainer Clip Reservoir Reservoir Cover Float Sw...

Page 71: ...replace e Transformer 1 Coil winding opened 1 Replace f Fuse Control Box 1 Blown 1 Check for short circuit and replace g Infrared Sensor 1 No power or defective 1 See IV D Bin Control Check h Mechani...

Page 72: ...eaking 1 Clean or replace c Hoses 1 Disconnected 1 Connect d Control Board 1 Defective 1 See IV B Diagnostic Procedure 3 Ice purge cycle will not start a Control Board 1 Defective 1 See IV B Diagnosti...

Page 73: ...leaks Replace drier and charge with refrigerant See V A Service for Refrigerant Lines 2 Refrigerant line or component restricted 2 Remove the restriction or component and replace the drier b Expansion...

Page 74: ...eak detector Repair leaks Replace drier and charge with refrigerant See V A Service for Refrigerant Lines 2 Refrigerant lines or components restricted 2 Remove the restriction or component and replace...

Page 75: ...ically If the water is found hard by testing install a softener 2 Low refrigerant pressures 2 Check charge check for possible leak repair re charge 3 Expansion valve bad 3 Replace 4 Evaporator bad 4 R...

Page 76: ...e an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG D...

Page 77: ...new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to ex...

Page 78: ...ow side parallel rack system a Refrigerant Recovery Using proper refrigerant practices close the liquid and suction line service valves at the rack system Then follow the steps below to recover the re...

Page 79: ...access valves to prevent a possible leak B Removal and Replacement of Compressor CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier un...

Page 80: ...over in its correct position On remote air cooled models connect the crankcase heater 16 Replace the panels in their correct positions 17 Turn on the power supply C Removal and Replacement of Expansio...

Page 81: ...bulb The bulb should be between the 10 and 2 o clock position on the tube Be sure to secure the bulb with the clamp and holder and to insulate it 11 Place the expansion valve cover in position 12 Rep...

Page 82: ...atched or cracked both the top bearing in the extruding head and the lower bearing in the housing should be replaced Instructions for removing the extruding head and housing are located later in this...

Page 83: ...Then turn on the power supply 4 Removal and Replacement of Auger 1 Drain the water from the evaporator a Move the power switch to the OFF position b Move the control switch to the DRAIN position c Mov...

Page 84: ...ly 7 Remove the insulation and the expansion valve bulb on the suction line 8 Disconnect the inlet and outlet tubing 9 Remove the allen head cap screws securing the evaporator to the lower housing 10...

Page 85: ...evaporator d Move the power switch to the OFF position 2 Turn off the power supply 3 Remove the panels 4 Remove the strap connecting the spout to the chute assembly then remove the spout 5 Remove the...

Page 86: ...to the ICE position Then turn on the power supply 7 Removal and Replacement of Gear Motor 1 Drain the water from the evaporator a Move the power switch to the OFF position b Move the control switch t...

Page 87: ...d outlet piping 5 Remove the corner barrier from the condenser 6 Remove the screws securing the condenser assembly then remove the assembly 7 Install the new condenser then attach the corner barrier 8...

Page 88: ...neath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 7 Recover the refrigerant and store it in an approve...

Page 89: ...lve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stop...

Page 90: ...ted in the Head Pressure table in the Performance Data section If it is not in the proper range verify the refrigerant charge 3 Check that the condenser drain temperature is stable I Removal and Repla...

Page 91: ...Recover the refrigerant and store it in an approved container 4 Before heating break off the stub on the dome to release the dome charge 5 Disconnect the headmaster 6 Place the new headmaster in posit...

Page 92: ...er s instructions 4 Recover the refrigerant from the icemaker and store it in an approved container 5 Remove the screw and the solenoid 6 Disconnect the valve and strainer 7 Place the new valve and st...

Page 93: ...he refrigerant and store it in an approved container 5 Remove the E P R valve 6 Place the new E P R valve in position 7 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to...

Page 94: ...side the evaporator Be sure to drain the water into the drain pan 4 Disconnect the terminals from the drain water valve 5 Remove the drain water valve from the bracket 6 Remove the drain pipe from the...

Page 95: ...board 4 Remove the control board 5 Adjust the dip switches on the new control board to the factory default settings See II C 4 a Default Dip Switch Settings 6 Install the new control board taking care...

Page 96: ...ing solutions from coming into contact with skin or eyes 4 After cleaning and sanitizing do not use ice made from the cleaning and sanitizing solutions Be careful not to leave any solution on the part...

Page 97: ...clamp on the reservoir hose in step 7 remove it before operation 10 In bad or severe water conditions clean the float switch assembly as described below See Fig 15 Otherwise continue to step 12 a Rem...

Page 98: ...ts turn off the power supply Remove the front panel then move the control switch to the DRAIN position Replace the front panel in its correct position 18 Turn on the power supply and allow the water s...

Page 99: ...2 Move the control switch to the ICE position then move the power switch to the ON position Replace the panels in their correct positions then turn on the power supply Make ice using the solution unti...

Page 100: ...control switch to the ICE position then replace the front panel in its correct position 15 Turn on the power supply to start the automatic icemaking process Allow the icemaker to run for about 30 min...

Page 101: ...eful not to overflow the pan This solution will flow down to the gear motor drain pan and out the drain line to sanitize these areas Repeat with a cup of clean water to rinse Icemaker and Dispenser Un...

Page 102: ...osition then turn on the power supply 7 Blow the icemaker water line out using the compressed air or carbon dioxide supply 8 Close the icemaker water supply line drain valve 2 Drain the evaporator 1 T...

Page 103: ...y line drain valve If connected to a closed loop system also open the condenser return line drain valve 4 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valv...

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