Hoshizaki F-1000MAF-22C Service Manual Download

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SERVICE MANUAL

ISSUED: JULY. 13, 1999

MODEL

HOSHIZAKI

MODULAR FLAKER

F-1000MAF-22C

NO:

73088

DEC. 15, 2003

REVISED:

Summary of Contents for F-1000MAF-22C

Page 1: ...SERVICE MANUAL ISSUED JULY 13 1999 MODEL HOSHIZAKI MODULAR FLAKER F 1000MAF 22C NO 73088 DEC 15 2003 REVISED ...

Page 2: ...tionoftheproblem IMPORTANT Only qualified service technicians should attempt to service or maintain this icemaker No 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 w...

Page 3: ...EMENT OF COMPRESSOR 29 4 REMOVAL AND REPLACEMENT OF DRIER 30 5 REMOVAL AND REPLACEMENT OF EXPANSION VALVE 31 6 REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY 32 7 REMOVAL AND REPLACEMENT OF FAN MOTOR 36 8 REMOVAL AND REPLACEMENT OF CONTROL WATER VALVE 36 9 REMOVAL AND REPLACEMENT OF FLUSH WATER VALVE 37 VII MAINTENANCE AND CLEANING INSTRUCTIONS 38 1 PREPARING THE ICEMAKER FOR LONG STORAGE 38 2 CLE...

Page 4: ...x 25 1 4 560 x 695 x 642mm EXTERIOR FINISH Stainless Steel Galvanized Steel Rear WEIGHT Net 172 lbs 78 kg Shipping 198 lbs 90 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger 1 6 HP Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Bi...

Page 5: ...FORMATION 1 CONSTRUCTION F 1000MAF 22 Water Supply Inlet Junction Box Condenser Fan Motor Compressor Drier Control Water Valve Bin Control Ice Chute Evaporator Expansion Valve Flush Water Valve Control Box Gear Motor ...

Page 6: ...el but not with the Parts List PRESSURE SWITCH CONNECTOR START CAPACITOR RUN CAPACITOR WATER CONTROL RELAY FLUSH TIMER TRANSFORMER GEAR MOTOR RELAY GEAR MOTOR CAP FLUSH ICE FAN MOTOR CAP GEAR MOTOR PROTECT RELAY STARTER CONTROL TIMER FUSE GEAR MOTOR FUSE POWER SWITCH FLUSH SWITCH CIRCUIT PROTECT RELAY ...

Page 7: ...7 III TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERATION CIRCUIT F 1000MAF 22 ...

Page 8: ...8 2 WIRING DIAGRAMS F 1000MAF 22 ...

Page 9: ...9 3 SEQUENCE OF ELECTRICAL CIRCUIT a When Power Switch is moved to ON position and Flush Switch to ICE position water starts to be supplied to Reservoir ...

Page 10: ...10 b When Reservoir has been filled Gear Motor starts immediately ...

Page 11: ...11 c Compressor starts about 60 sec after Gear Motor starts ...

Page 12: ...12 d Bin Control operates and about 6 sec later Compressor and Gear Motor stop simultaneously ...

Page 13: ...13 e Low Water ...

Page 14: ...14 f Dirty Air Filter Pressure Switch to OPEN Compressor and Gear Motor operates intermittently ...

Page 15: ...15 g When Flush Switch is moved to FLUSH position Flush Water Valve opens and flushes Reservoir and Evaporator ...

Page 16: ...16 h When Flush Timer operates for 15 min every 12 hours ...

Page 17: ... 208 230V are supplied to Circuit Protect Relay it protects the circuit from miswiring If the power supply is properly connected the contact of Circuit Protect Relay does not move even when the coil is energized ...

Page 18: ...18 j When input voltage is too low Less than 70 Gear Motor Fuse 1 5A is blown causing the Compressor and Gear Motor to turn off immediately ...

Page 19: ...R CONTROL RELAY 5 CONTROL WATER VALVE 6 FLUSH TIMER 7 FLUSH SWITCH 8 FLUSH WATER VALVE 9 BIN CONTROL 10 GEAR MOTOR RELAY 11 GEAR MOTOR 12 FAN MOTOR 13 COMPRESSOR 14 PRESSURE SWITCH 15 HEATER ON OFF ON OFF ON OFF ON OFF ON OFF 1 2 2 3 FLUSH ICE ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF 1 sec 60 sec 6 sec 1 sec 60 sec UPPER LOWER BOTTOM 4 TIMING CHART ...

Page 20: ...LUSH WATER VALVE 9 BIN CONTROL 10 GEAR MOTOR RELAY 11 GEAR MOTOR 12 FAN MOTOR 14 PRESSURE SWITCH 15 HEATER ON OFF ON OFF ON OFF ON OFF ON OFF 1 2 2 3 FLUSH ICE ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF UPPER LOWER BOTTOM LOW WATER FLUSH TIMER 21 min every 12 hr 150 sec 1 sec 150 sec 90 sec 60 sec 90 sec 60 sec 1 sec 13 COMPRESSOR ...

Page 21: ... FLUSH WATER VALVE 9 BIN CONTROL 10 GEAR MOTOR RELAY 11 GEAR MOTOR 12 FAN MOTOR 14 PRESSURE SWITCH 15 HEATER ON OFF ON OFF ON OFF ON OFF ON OFF 1 2 2 3 FLUSH ICE ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF UPPER LOWER BOTTOM FLUSH SWITCH PRESSURE SWITCH FLUSH ICE OFF ON 150 sec 1 sec 90 sec 60 sec 13 COMPRESSOR 1 sec 1 sec 60 sec ...

Page 22: ...ATER 70 103 390 95 360 92 348 CONSUMPTION PER 24 HR 80 89 338 87 327 84 317 90 81 307 80 304 76 288 gal day l day 100 74 279 72 271 67 252 EVAPORATOR OUTLET TEMP 70 14 10 14 10 14 10 F C 80 14 10 18 8 18 8 90 18 8 18 8 21 6 100 21 6 21 6 21 6 HEAD PRESSURE 70 170 11 9 170 11 9 170 11 9 80 199 14 0 199 14 0 199 14 0 90 228 16 0 228 16 0 228 16 0 PSIG kg sq cmG 100 258 18 1 258 18 1 258 18 1 SUCTION...

Page 23: ...2 Wait till water is supplied j Plug and Receptacle Control Box 1 Disconnected 1 Connect 2 Terminal out of Plug or Receptacle 2 Insert Terminal back in position 2 Water flow does not stop and the icemaker will not start a Water Control Relay 1 Contact fused 1 Replace 2 Coil winding opened 2 Replace b Float Switch 1 Bad contacts 1 Check for continuity and replace 2 Float does not move freely 2 Clea...

Page 24: ...Gear Motor starts but Compressor will not start or operates intermittently a X2 Relay on Control Timer 1 Bad contacts 1 Replace Check for continuity and replace 2 Coil winding opened 2 Replace Timer b Starter 1 Bad contacts 1 Check for continuity and replace 2 Coil winding opened 2 Replace 3 Loose Connections 3 Tighten c Start Capacitor or Run Capacitor 1 Defective 1 Replace d Compressor 1 Loose c...

Page 25: ... b High side Pressure Too High 1 Dirty Air Filter or Condenser 1 Clean 2 Ambient or condenser water temperature too warm 2 Get cooler 3 Fan rotating too slow 3 See 3 1 a Fan Motor 4 Condensing unit out of order 4 Check condensing unit c Expansion Valve not adjustable 1 Low side pressure too low 1 Replace 2 Low side pressure too high 2 See if Expansion Valve Bulb is mounted properly and replace the...

Page 26: ...26 3 OTHERS ...

Page 27: ...ackward 3 Allow the Vacuum Pump to pull down to a 29 9 Hg vacuum Evacuating period de pends on pump capacity 4 Close the Low side Valve and High side Valve on the Service Manifold 5 Disconnect the Vacuum Pump and attach a Refrigerant Service Cylinder to the High side line Remember to loosen the connection and purge the air from the Hose See the Nameplate for the required refrigerant charge Hoshiza...

Page 28: ...s recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere 3 Do not use silver alloy or copper alloy containing Arsenic 4 In its liquid state the refrigerant can cause frostbite due to the low tem perature 9 Close the Refrigerant Access Valve and disconnect the Hoses and Service Manifold 10 Cap the Access Valve to prevent a possible leak ...

Page 29: ...g equipment WARNING When repairing a refrigerant system be careful not to let the burner flame contact any electrical wires or insulation 5 Remove the Bolts and Rubber Grommets 6 Slide and remove the Compressor Unpack the new Compressor package Install the new Compressor 7 Attach the Rubber Grommets of the prior Compressor 8 Sandpaper the Discharge Suction and Access Pipes 9 Place the Compressor i...

Page 30: ...r all other repairs or replacement have been made 1 Turn off the power supply and remove the panels 2 Recover the refrigerant and store it in an approved container if required by an applicable law 3 Remove the Drier using brazing equipment 4 Install the new Drier with the arrow on the Drier in the direction of the refrigerant flow Use nitrogen gas at the pressure of 3 4 PSIG when brazing the tubin...

Page 31: ...alve using brazing equipment 5 Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 3 4 PSIG WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 6 Install the new Drier 7 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 8 Evacuate the system Charge it with refrigerant Fo...

Page 32: ...f the Cutter 9 Remove the Rubber O ring and the Nylon Ring at the top of the Evaporator EXTRUDING HEAD 10 Remove the four Socket Head Cap Screws and lift off the Extruding Head 11 Replace the Bearing inside the Extruding Head if it exceeds the wear tolerance of 0 02 or is scratched Note Replacing the Bearing requires a bearing press adaptor If it is not available replace the whole Extruding Head A...

Page 33: ... Screws securing the Evaporator with the Bearing Lower 19 Lift off the Evaporator BEARING LOWER AND MECHANICAL SEAL 20 The Mechanical Seal consists of two parts One moves along with the Auger and the other is fixed on the Bearing Lower If the contact surfaces of these two parts are worn or scratched the Mechanical Seal may cause water leaks and should be replaced 21 Remove the O ring on the Bearin...

Page 34: ...en replacing the Evaporator a Braze the new Evaporator with nitrogen gas flowing at the pressure of 3 4 PSIG b Replace the Drier c Check for leaks using nitrogen gas 140 PSIG and soap bubbles d Evacuate the system Charge it with refrigerant For the air cooled and water cooled models see the Nameplate for required refrigerant charge and type For the remote air cooled models see the label on the Con...

Page 35: ...Mechanical Seal O ring Bearing Lower Bolt Washer Coupling Spline Rubber O ring Nylon Ring Bolt Washer Cutter Extruding Head Washer Socket Head Cap Screw Evaporator Washer Socket Head Cap Screw Barrier Gear Motor ...

Page 36: ...Turn off the power supply remove the panels and close the Water Supply Line Shut off Valve 2 Disconnect the Terminals from the Control Water Valve 3 Loosen the Fitting Nut on the Control Water Valve Inlets and remove the Control Water Valve Do not lose the Packings inside the Fitting Nut 4 Remove the Water Supply Hose from the Control Water Valve 5 Install the new Control Water Valve 6 Assemble th...

Page 37: ...et 5 Remove the Drain Pipe from the Flush Water Valve 6 Connect the Drain Pipe to the new Flush Water Valve and place the valve in position 7 Connect the Hose to the Flush Water Valve and secure it with the Clamp 8 Pour water into the Reservoir and check for water leaks on the Flush Water Valve 9 Open the Water Supply Line Shut off Valve and turn on the power supply 10 Move the Flush Switch to the...

Page 38: ...t sub freezing temperatures using air or carbon dioxide Shut off the icemaker until the proper ambient temperature is resumed 1 Run the icemaker with the Water Supply Line Shut off Valve closed 2 Open the Drain Valve and blow out the water inlet line by using air pressure 3 Turn off the power supply 4 Remove the Front Panel 5 Move the Flush Switch on the Control Box to the FLUSH position 6 Turn on...

Page 39: ...water as follows Cleaning solution 4 8 fl oz of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 0 8 gal of water This is a minimum amount Make more solution if necessary Sanitizing solution 2 5 fl oz of a 5 25 sodium hypochlorite solution chlorine bleach with 5 gal of water IMPORTANT For safety and maximum effectiveness use the solution immediately after diluti...

Page 40: ... for about 10 minutes before the operation Then turn on the power supply and make ice using the solution until the icemaker stops icemaking 15 Remove the Front Panel 16 Move the Flush Switch to the FLUSH position to drain the cleaning solution 17 Move the Flush Switch to the ICE position 18 Replace the Front Panel in its correct position 19 Open the Water Supply Line Shut off Valve and supply wate...

Page 41: ... and supply water to the Reservoir 14 Turn off the power supply when the Gear Motor starts 15 Drain out all water from the water line See 4 through 7 in STEP 2 16 Move the Flush Switch to the ICE position STEP 4 Use the sanitizing solution to sanitize removed parts 1 Remove the Thumbscrew securing the Bin Control Switch on the Chute Assembly 2 Remove the Band connecting the Spout with the Chute As...

Page 42: ... left on these parts they will rust 12 Replace the removed parts and the panels 13 Turn on the power supply and run the icemaker 14 Turn off the power supply after 30 minutes 15 Pour warm water into the Storage Bin to melt all ice and then clean the Bin Liner with the solution 16 Flush out any solution from the Storage Bin 17 Turn on the power supply and start the automatic icemaking process IMPOR...

Page 43: ... local distributor about inspection and maintenance service Toobtainthenameandphonenumberofyourlocaldistributor call Hoshizaki Technical Support at 1 800 233 1940 1 Stainless Steel Exterior To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up 2 Storage Bin and Scoop Wash your hands before remo...

Page 44: ...clogged the icemaker s performance will be reduced Check the filter at least twice a month When clogged use warm water and a neutral cleaner to wash the filter 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 ...

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