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47

V. REMOVAL AND REPLACEMENT OF COMPONENTS

1. REFRIGERATION CIRCUIT

WARNING

This machine contains flammable refrigerant. Do not attempt to break into the refrigerant
circuit unless qualified, competent and authorised to do so.

If any component of the refrigeration circuit requires removal or replacement, please contact
the manufacturer:

HOSHIZAKI EUROPE LIMITED
Telford 70 Stafford Park 7, Telford, Shropshire TF3 3BQ UK
Tel: +44 (0)1952-291777
Fax: +44 (0)1952-292777

[a] APPLICABLE PARTS

Refrigerant (R290)
Compressor
Evaporator Casing
Air-cooled Condenser
Drier
Thermal Expansion Valve (with MOP)

2. EVAPORATOR ASSEMBLY

See the exploded view under “III. 3. ICEMAKING MECHANISM”.

1) Push the stop button to drain the water in the evaporator.

2) Disconnect the power source.

3) Remove the panels.

4) Remove the three thumbscrews, and take off the spout from the evaporator.

5) Remove the bin control switch.

6) Remove the spout gasket at the top of the evaporator.

CUTTER

7) Remove the bolt and lift off the cutter.

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Summary of Contents for FM-300AKE-HC

Page 1: ...NO F087 880 ISSUED JUL 9 2012 REVISED APR 25 2014 SERVICE MANUAL HOSHIZAKI MODULAR ICE MAKER MODEL FM 300AKE HC FM 300AKE HCN FM 480AKE HC FM 480AKE HCN ...

Page 2: ...RUCTIONS 12 1 EXTRUDING HEAD UPPER BEARING HOUSING LOWER BEARING 12 2 MECHANICAL SEAL 12 3 GEAR MOTOR 13 4 CONDENSER AIR COOLED MODEL ONLY 13 5 AIR FILTER AIR COOLED MODEL ONLY 13 6 CONTROL WATER VALVE 14 7 CLEANING OF WATER SYSTEM 15 III TECHNICAL INFORMATION 17 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 17 2 WIRING DIAGRAM 18 a WIRING DIAGRAM 18 b CONTROL BOX LAYOUT 22 3 ICEMAKING MECHANISM 23 a EV...

Page 3: ...ING COMPRESSOR STARTING TIME 36 6 PROTECTORS 36 a INDICATION 36 7 ERROR CODES 37 8 PERFORMANCE DATA 31 a FM 300AKE HC 39 b FM 300AKE HCN 40 c FM 480AKE HC 41 d FM 480AKE HCN 42 IV SERVICE DIAGNOSIS 43 1 NO ICE PRODUCTION 43 2 LOW ICE PRODUCTION 45 3 OTHERS 45 V REMOVAL AND REPLACEMENT OF COMPONENTS 47 1 REFRIGERATION CIRCUIT 47 a APPLICABLE PARTS 47 2 EVAPORATOR ASSEMBLY 47 3 CONTROL WATER VALVE 4...

Page 4: ...1 I SPECIFICATIONS 1 DIMENSIONS SPECIFICATIONS a FM 300AKE HC Auxiliary code D 0 or earlier ...

Page 5: ...2 b FM 300AKE HC Auxiliary code D 1 or later ...

Page 6: ...3 c FM 300AKE HCN Auxiliary code D 0 or earlier ...

Page 7: ...4 d FM 300AKE HCN Auxiliary code D 1 or later ...

Page 8: ...5 e FM 480AKE HC Auxiliary code D 0 or earlier ...

Page 9: ...6 f FM 480AKE HC Auxiliary code D 1 or later ...

Page 10: ...7 g FM 480AKE HCN Auxiliary code D 0 or earlier ...

Page 11: ...8 h FM 480AKE HCN Auxiliary code D 1 or later ...

Page 12: ...ut Reservoir Evaporator Gear Motor 2 CONSTRUCTION a FM 300AKE HC N Auxiliary code D 0 or earlier Compressor Fan Motor Air Cooled Condenser Flush Water Valve Control Box Control Water Valve Bin Control Switch ...

Page 13: ...10 b FM 480AKE HC N Auxiliary code D 0 or earlier Reservoir Evaporator Gear Motor Spout Control Water Valve Control Box Flush Water Valve Compressor Bin Control Switch Air Cooled Condenser Fan Motor ...

Page 14: ...11 c FM 300AKE HC N FM 480AKE HC N Auxiliary code D 1 or later See a or b for the entire construction Spout Reed Switch Bin Control Spout Cover Spring Reed Switch Spout Sw Chute Actuator ...

Page 15: ... on the water quality and conditions but normally the bearings should be checked for wear after a total of 8 000 10 000 hour operation from installation date Note The clearance between the auger blades and the evaporator interior is 0 4 0 5 mm If the bearings and rotating parts are worn out to create a larger clearance the evaporator interior may be damaged The diameters differ by 0 8 1 0 mm If th...

Page 16: ... to a large amount of water at one time water may enter the gear case Always drain the water circuit before removing the auger for service 4 CONDENSER Check the condenser once a year and clean if required by using a brush or vacuum cleaner More frequent cleaning may be required depending on the location of the icemaker 5 AIR FILTER Plastic mesh air filters remove dirt or dust from the air and keep...

Page 17: ...ap 3 Disconnect the inlet hose from the water valve 4 Clean the filter packing using a brush 5 Replace the filter packing and inlet hose in their correct positions 6 Open the water supply tap 7 Connect the power source 8 Check for leaks Inlet Hose Filter Packing Control Water Valve ...

Page 18: ...anitiser immediately 7 Do not use any ammonia type cleaners on any part of the icemaker CAUTION Do not use ice produced with cleaning and sanitizing solutions Be sure none remains in the storage bin on completion of cleaning STEP 1 Dilute the solutions with water as follows Cleaning solution Nickel Safe Ice Machine Cleaner by The Rectorseal Corporation or similar Prepare approximately 3 L of solut...

Page 19: ... machine to continue icemaking for a further 20 minutes Open the access flap and press the stop button 12 Allow time for the gear motor to stop and the water system to drain 13 Allow the icemaker to make ice for approximately 10 minutes 14 Pour warm water into the storage bin to melt any ice down the drain Note 1 If the machine has heavy deposits of scale repeat the complete cleaning procedure 2 D...

Page 20: ...17 III TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT Pressure Switch Cut out 2 26 0 15 0 MPa Cut in 1 57 0 15 MPa FM 480AKE HC N only 400 mm ...

Page 21: ...18 2 WIRING DIAGRAM a WIRING DIAGRAM FM 300AKE HC N Auxiliary code D 0 or earlier ...

Page 22: ...19 FM 300AKE HC N Auxiliary code D 1 or later ...

Page 23: ...20 FM 480AKE HC N Auxiliary code D 0 or earlier ...

Page 24: ...21 FM 480AKE HC N Auxiliary code D 1 or later ...

Page 25: ...LLER BOARD OPERATION X1 POWER RELAY CONTROL WATER VALVE ON BOARD X2 POWER RELAY FLUSH WATER VALVE ON BOARD X3 POWER RELAY GEAR MOTOR ON BOARD X4 POWER RELAY COMPRESSOR ON BOARD S3 OPERATION SWITCH OL CIRCUIT PROTECTOR 10A 300AKE HC 20A 480AKE HC C1 CAPACITOR GM1 F FUSE 3 15A TR TRANSFORMER ...

Page 26: ...ugget Type Screw Bolt Spring Washer Cutter Sealing Bolt Flange Belt Heater provided for some models Evaporator Coupling Housing O ring Mechanical Seal Auger Pin Gear Motor Screw Extruding Head Screw Bolt Spring Washer Cutter Extruding Head ...

Page 27: ...to a column shape with the path resistance d HOUSING The cast bronze housing is provided with a press fit plastic bearing inside and fixed on the bottom of the evaporator for connection with the gear motor e MECHANICAL SEAL The mechanical seal on the lower auger bearing prevents icemaking water leaks into the evaporator The mating surfaces are made of ceramic and carbon f COUPLING SPLINE JOINT The...

Page 28: ... resulting in breaking the welded joints To avoid the load the flange has been changed to a separate part to be secured together with the extruding head by using sealing bolts j SEALING BOLT Sometimes the icemaking operation may produce white solids on the drip pan They are deposits of silica and calcium contents in the icemaking water leaking from the sealing bolt The bolt is provided with retain...

Page 29: ... check the actuator for proper dimensions 1 Remove the bin control switch from the chute 2 Move the actuator to the maximum operation angle as shown below top Check that the actuator is about 13 mm away from the barrier If not replace the whole bin control switch assembly l BIN CONTROL SWITCH Auxiliary code D 1 or later The bin control switch is composed of a reed switch attached to the spout and ...

Page 30: ... with an error Be sure to attach the proper ice detector The actuator is composed of two components bonded The letters C and F are stamped on the fitting part The type of icemaker can be distinguished by boss fitting position Flake Nugget Spout Spout Cover Chute Actuator Actuator Hinge Actuator Ice Detector Icemaking Bin Control F C Magnet Ice Detector Magnet Reed Switch Boss fitting position C Nu...

Page 31: ...the STOP position then to the RUN position Normal Condition Abnormal Condition Band moves and presses microswitch n SPOUT SPOUT COVER Auxiliary code D 1 or later The spout and spout cover are connected to the evaporator casing with a removable flange These are the passage to deliver ice formed inside the evaporator casing into the chute The spout is provided with a reed switch ant the spout cover ...

Page 32: ... immediately After 5 minutes the compressor starts to begin icemaking operation In normal operation the icemaker shuts down when the storage bin fills up to trip the bin control switch or the stop button is pressed When the compressor operates for 6 hours in total and continuously for more than 10 minutes the icemaker supplies water until the reservoir fills up and starts a drain cycle After 10 mi...

Page 33: ...30 b TIMING CHART ...

Page 34: ...L NUMBER 1 Press and hold the maintenance B button and move the operation switch to the ON position 2 When the display shows 99 release the maintenance B button 3 Press the stop button to increase the number or press the ice button to decrease the number until it matches the model number on the wiring label 4 Press the maintenance B button to complete the setting and start icemaking operation in t...

Page 35: ...tton The display shows the following items one by one every time the ice button is pressed This function is available in the ice or stop mode Press and hold MAINTENANCE A Compressor operating hours on display a Press ICE Cycle time on display b Press ICE Model number on display c Press ICE Software version on display d Release MAINTENANCE A 1 3 2 4 ...

Page 36: ...ppears in the display to show the end of the cycle time display mode If no cycle time is recorded the display shows only Minutes are indicated as follows o 0 to 9 0 to 9 minutes A 0 to 9 10 to 19 minutes b 0 to 9 20 to 29 minutes D 0 to 9 30 to 39 minutes d 0 to 9 40 to 49 minutes E 0 to 9 50 to 59 minutes Seconds are indicated as 0 to 5 0 to 9 e g o9 48 9 minutes 48 seconds b7 36 27 minutes 36 se...

Page 37: ...on is pressed This function is available in the ice or stop mode Press and hold MAINTENANCE A Compressor operating hours on display c a Press STOP Error log on display 8 records at maximum Press STOP on display end of error log display mode Press STOP Ongoing error on display Release MAINTENANCE A Note 1 The display does not show the ongoing error even if the stop button is pressed while the error...

Page 38: ...OR OPERATING HOURS With the power switch turned off press and hold the ice stop and maintenance A buttons Move the operation switch to the ON position Release the buttons when the display shows the ice mode Now the compressor operating hours are reset When the compressor starts in 15 seconds after the water supply cycle ends the error log is not set to be updated After resetting the compressor ope...

Page 39: ...ation switch to the ON position Release the button when the display shows the ice mode The compressor starts in 30 seconds after the water supply cycle ends 6 PROTECTORS a INDICATION When an operational error occurs E_ will appear and blink in the display 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 Then ...

Page 40: ...er board while rotation sensor signals gear motor rotation or current flows E5 Gear Motor Drive Element Error Gear motor relay is OFF with gear motor protective circuit detector ON Whole unit stops Power supply Turn OFF Turn ON Miswiring gear motor magnet switch or relay Replace controller board E8 Discharge Pipe Temperature Error Discharge pipe thermostat is OFF Whole unit stops Power supply Turn...

Page 41: ...t reset for more than 60 seconds after water supply Whole unit stops until reservoir fills up Only control water valve operates intermittently for 5 minutes Automatically resets after reservoir fills up Water supply interruption control water valve not opening flush water valve not closing float switch water leak c2 Abnormal High Side Pressure Pressure switch stays OFF for 5 seconds or condenser t...

Page 42: ... 0 5 0 10 20 30 40 Water Consumption m day 3 5 4 4 5 5 5 5 0 10 20 30 40 Amperage A 17 19 21 23 25 27 0 10 20 30 40 Wattage kWh day 700 900 1100 1300 1500 1700 0 10 20 30 40 50 Head Pressure kPa 200 220 240 260 280 300 0 10 20 30 40 50 Suction Pressure kPa The horizontal axis shows the ambient temperature It refers to the data of at wt 10 10 21 15 32 21 ...

Page 43: ... 20 30 40 Water Consumption m day 3 5 4 4 5 5 5 5 0 10 20 30 40 Amperage A 17 19 21 23 25 27 0 10 20 30 40 Wattage kWh day 700 900 1100 1300 1500 1700 0 10 20 30 40 50 Head Pressure kPa 200 220 240 260 280 300 0 10 20 30 40 50 Suction Pressure kPa The horizontal axis shows the ambient temperature It refers to the data of at wt 10 10 21 15 32 21 ...

Page 44: ...900 1100 1300 1500 1700 0 10 20 30 40 Head Pressure kPa 150 170 190 210 230 250 0 10 20 30 40 Suction Pressure kPa 0 2 0 25 0 3 0 35 0 4 0 45 0 5 0 55 0 6 0 10 20 30 40 Water Consumption m day 22 24 26 28 30 32 0 10 20 30 40 Wattage kWh day The horizontal axis shows the ambient temperature It refers to the data of at wt 10 10 21 15 32 21 ...

Page 45: ...24 26 28 30 32 0 10 20 30 40 Wattage kWh day 700 900 1100 1300 1500 1700 0 10 20 30 40 Head Pressure kPa 150 170 190 210 230 250 0 10 20 30 40 Suction Pressure kPa 0 2 0 25 0 3 0 35 0 4 0 45 0 5 0 55 0 6 0 10 20 30 40 Water Consumption m day The horizontal axis shows the ambient temperature It refers to the data of at wt 10 10 21 15 32 21 ...

Page 46: ...1 Disconnected 1 Connect h Plug and receptacle control box 2 Terminal out of plug or receptacle 2 Insert terminal back in position i Reed switch spout 1 Tripped 1 See 1 3 a j Overload protector 1 Tripped 2 Reset 1 The icemaker will not start k Model number 1 Incorrect 2 Set correct number See III 5 b SETTING MODEL NUMBER 1 Contacts fused 1 Replace controller board a Water control relay controller ...

Page 47: ... contacts 2 Check for continuity and replace 1 Bad contacts 1 Check for continuity and replace controller board a X4 relay controller board 2 Coil winding opened 2 Replace controller board 1 Bad contacts 1 Check for continuity and replace X6 relay b X6 relay 2 Coil winding opened 2 Replace X6 relay 1 Loose connections 1 Tighten 2 Motor winding opened or earthed 2 Replace b Compressor 3 Motor prote...

Page 48: ... production d Evaporator 1 Evaporator pipe crushed 1 Replace 3 OTHERS PROBLEM POSSIBLE CAUSE REMEDY 1 Bearing worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade a Fan motor condenser unit 3 Fan blade does not move freely 3 Replace 1 Bearings worn out or cylinder valve defective 1 Replace b Compressor 2 Mounting pad out of position 2 Reinstall c Refrigerant lines 1 Rub or touch lines or ot...

Page 49: ...se 1 Clean or replace 2 Overflow from reservoir Water does not stop c Float switch 1 Bad contacts 1 Check for continuity and replace a Power supply voltage 1 Too high or too low 1 Connect the unit to a power supply of proper voltage 3 Gear motor protector operates frequently b Evaporator assy 1 Bearings or auger worn out 1 Replace bearing or auger ...

Page 50: ...ford Shropshire TF3 3BQ UK Tel 44 0 1952 291777 Fax 44 0 1952 292777 a APPLICABLE PARTS Refrigerant R290 Compressor Evaporator Casing Air cooled Condenser Drier Thermal Expansion Valve with MOP 2 EVAPORATOR ASSEMBLY See the exploded view under III 3 ICEMAKING MECHANISM 1 Push the stop button to drain the water in the evaporator 2 Disconnect the power source 3 Remove the panels 4 Remove the three t...

Page 51: ...rer HOUSING AND MECHANICAL SEAL 12 The mechanical seal consists of two parts One part rotates with the auger the other is static and is fitted into a top recess in the housing If the contact surfaces of these two parts become worn or scratched the mechanical seal may leak water and should be replaced 13 Remove the O ring on the top outer edge of the housing 14 Remove the four bolts and lift the ho...

Page 52: ...sen the fitting nut on the control water valve Inlets and remove the control water valve Do not lose the packings inside the fitting nut 7 Install the new control 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 4 FLUSH WATER VALVE 1...

Page 53: ...lushing 15 Push the ice button 16 Refit the panels in their correct position 5 CONTROLLER BOARD IMPORTANT A single type controller board is supplied as a service board Some modifications and adjustment will be required to fit the icemaker models Do not repair any parts and electronic devices on the controller board in the field Replace the whole board with a new service board a MODIFICATION 1 Chec...

Page 54: ...e controller board 5 Remove the controller board from the control box 6 Install the new controller board and reassemble the control box in the reverse order of the removal procedure 7 Replace the front panel in its correct position 8 Connect the power source ...

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