Hoshizaki FM-481AGE Service Manual Download

Page: 1 / 68

NO.

E2AH-582

ISSUED: NOV. 12, 2001

REVISED: SEP. 27, 2002

HOSHIZAKI

MODULAR FLAKER

MODEL

FM-481AGE

FM-481AWGE

FM-481AGE-N

FM-481AWGE-N

SERVICE MANUAL

Summary of Contents for FM-481AGE

Page 1: ... ISSUED NOV 12 2001 REVISED SEP 27 2002 REVISED SEP 27 2002 HOSHIZAKI HOSHIZAKI MODULAR FLAKER MODULAR FLAKER MODEL MODEL FM 481AGE FM 481AGE FM 481AWGE FM 481AWGE FM 481AGE N FM 481AGE N FM 481AWGE N FM 481AWGE N SERVICE MANUAL SERVICE MANUAL ...

Page 2: ...ONNECTIONS 23 23 3 WATER SUPPLY AND DRAIN CONNECTIONS 3 WATER SUPPLY AND DRAIN CONNECTIONS 24 24 4 START UP PROCEDURE 4 START UP PROCEDURE 25 25 IV MAINTENANCE AND CLEANING INSTRUCTIONS IV MAINTENANCE AND CLEANING INSTRUCTIONS 27 27 1 EXTRUDING HEAD HOUSING BEARING AUGER BEARING 1 EXTRUDING HEAD HOUSING BEARING AUGER BEARING 27 27 2 MECHANICAL SEAL 2 MECHANICAL SEAL 27 27 3 GEAR MOTOR 3 GEAR MOTOR...

Page 3: ...NOSIS VII SERVICE DIAGNOSIS 47 47 1 NO ICE PRODUCTION 1 NO ICE PRODUCTION 47 47 2 LOW ICE PRODUCTION 2 LOW ICE PRODUCTION 49 49 3 OTHERS 3 OTHERS 49 49 VIII REMOVAL AND REPLACEMENT OF COMPONENTS VIII REMOVAL AND REPLACEMENT OF COMPONENTS 51 51 1 SERVICE FOR REFRIGERANT LINES 1 SERVICE FOR REFRIGERANT LINES 51 51 a SERVICE INFORMATION a SERVICE INFORMATION 51 51 b REFRIGERANT RECOVERY b REFRIGERANT...

Page 4: ...1 1 E2AH5820209 E2AH5820209 I SPECIFICATIONS I SPECIFICATIONS 1 DIMENSIONS CONNECTIONS 1 DIMENSIONS CONNECTIONS a FM 481AGE FM 481AGE N a FM 481AGE FM 481AGE N Top View ...

Page 5: ...2 2 E2AH5820209 E2AH5820209 b FM 481AWGE FM 481AWGE N b FM 481AWGE FM 481AWGE N Top View ...

Page 6: ...3 3 E2AH5820209 E2AH5820209 c WITH STORAGE BIN B 300_F c WITH STORAGE BIN B 300_F ...

Page 7: ...TEM HARVESTING SYSTEM Auger type Direct driven Auger 200W Gear Motor COMPRESSOR CONDENSER HEAT REJECTION EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE Hermetic Compressor Model RS80C2E CAZ 219 Fin and Tube type forced air cooling 3150W Ambient temp 32 C Water temp 21 C Copper Tube on Cylinder Thermostatic Expansion Valve R404A 770g BIN CONTROL SYSTEM ICE MAKING WATER CONTROL Mechanical Bin Con...

Page 8: ...ear side Cond Outlet Rc 3 8 Connected at rear side ICE MAKING SYSTEM HARVESTING SYSTEM Auger type Direct driven Auger 200W Gear Motor COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE Hermetic Compressor Model RS80C2E CAZ 219 Water cooled Tube in Tube Type Copper Tube on Cylinder Thermostatic Expansion Valve R404A 450g BIN CONTROL SYSTEM ICE MAKING WATER CONTROL Mechanical Bin...

Page 9: ...RVESTING SYSTEM Auger type Direct driven Auger 200W Gear Motor COMPRESSOR CONDENSER HEAT REJECTION EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE Hermetic Compressor Model RS80C2E CAZ 219 Fin and Tube type forced air cooling 2500W Ambient temp 32 C Water temp 21 C Copper Tube on Cylinder Thermostatic Expansion Valve R404A 770g BIN CONTROL SYSTEM ICE MAKING WATER CONTROL Mechanical Bin Control T...

Page 10: ...rear side Cond Outlet Rc 3 8 Connected at rear side ICE MAKING SYSTEM HARVESTING SYSTEM Auger type Direct driven Auger 200W Gear Motor COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE Hermetic Compressor Model RS80C2E CAZ 219 Water cooled Tube in Tube Type Copper Tube on Cylinder Thermostatic Expansion Valve R404A 450g BIN CONTROL SYSTEM ICE MAKING WATER CONTROL Mechanical Bi...

Page 11: ...nit is not equipped with an Ice Compressor Condenser and Control Assemblies As the unit is not equipped with an Ice Storage Bin this must be purchased separately as an optional extra Storage Bin this must be purchased separately as an optional extra Pressure Switch Pressure Switch Control Box Control Box Evaporator Evaporator Gear Motor Gear Motor Flush Water Valve Flush Water Valve Ice Chute Ice ...

Page 12: ...ad Extruding Head Belt Heater Belt Heater Socket Head Cap Screw Socket Head Cap Screw w Plastic Seal w Plastic Seal Casing Casing Auger Auger Mechanical Seal Mechanical Seal Socket Head Cap Screw Socket Head Cap Screw Housing Housing Coupling Coupling Gear Motor Gear Motor Rotation Sensor Rotation Sensor ...

Page 13: ...ept for the Dip Switch settings The Operation Board is equipped with the Display 7 segments 2 digits and the three Operation Buttons ICE STOP and OPTION which are for checking the operating conditions during servicing and user operation The Main Board is equipped with Relays for the Compressor Gear Motor Control Water Valve and Flush Water Valve a OPERATION PANEL Positioned on the left side of the...

Page 14: ... interlock errors Check error records for non interlock stoppages c__ indication Button Operations Operator Indication Function Button Operation Start icemaking Ice Button User Stop icemaking after drain Stop Button Indicate total compressor operating hours Option Button Indicate cycle time Option Button Ice Button Indicate error records Option Button Stop Button Indicate ongoing non interlock err...

Page 15: ... 7 seconds à Icemaking starts Automatic drain After 6 hours from the last drain cycle or after 1 hour with Storage Bin full Service mode Shortens the 5 minute delay before the initial icemaking cycle for ease of service Water supply à Reservoir fills à Gear Motor ON à Compressor ON after 30 seconds Production line inspection mode Switches to the following controls for 30 minutes to shorten the fin...

Page 16: ...T NO STAMP K6 OPERATION BOARD K3 FAN MOTOR FOR CONTROL BOX 12V DC OUTPUT K2 CONTROL WATER VALVE K8 ROTATION SENSOR K4 GEAR MOTOR SENSOR K7 BIN CONTROL SWITCH K7 PRESSURE SWITCH K2 FLUSH WATER VALVE K1 24V AC INPUT DIP SWITCH K5 FLOAT SWITCH ...

Page 17: ... d SUB BOARD LAYOUT 14 E2AH5820209 CN1 MAIN BOARD 12V DC DIP SWITCH Note As the previous Timer Board marking is applied the Sub Board is marked 24V But the actual input is 12V ...

Page 18: ...on Switch on STOP 1 While pressing the Option Button move the Operation Switch to the RUN position 2 Release the Option Button when the Display shows the total compressor operating hours _ _ thousand hours 3 The Display illuminates ICE and the icemaker starts up in the shortened startup mode 2 Indicate total operating hours The total operating hours are indicated in two digits _ _ thousand hours b...

Page 19: ...pply ON Operation Switch on RUN 1 Keep on pressing the Option Button until step 4 2 The Display changes from the normal indication to the total operating hours 3 While pressing the Option Button Press the Stop Button once 4 The Display indicates the error record 5 Release the Option Button The Display changes back to the normal indication ex The Display indicates the record of the last eight error...

Page 20: ... to the RUN position 2 When the Display illuminates ICE release the Stop Button first and then the Option Button 5 Indicate cycle time The cycle time to estimate the current ice production capacity is indicated by the following button operation This cycle time means the time since the Float Tank fills up during Compressor operation until the next icemaking water supply starts The last five cycles ...

Page 21: ...depends on ambient and water temperatures See VI 4 PERFORMANCE DATA Cycle Time reference Ice Production Capacity kg d CM 230 series FM 250 series FM 481 series FM 1000 series FM 2000 series 100 9 min 10 sec 200 4 min 35 sec 300 3 min 03 sec 400 2 min 18 sec 2 min 57 sec 500 1 min 50 sec 2 min 21 sec 600 1 min 32 sec 1 min 58 sec 700 1 min 19 sec 1 min 41 sec 800 1 min 28 sec 900 1 min 19 sec 1000 ...

Page 22: ...s Power supply Turn OFF Turn ON Replace Controller Board E6 Phase Reversal Error Phase Reversal Whole unit stops Power supply Turn OFF Turn ON 3 phase models only Phase reversal E7 Failure Precaution FM 481 only Gear Motor Amperage Sensor has operated more than 10 times E7 blinks N A Damage to Evaporator assembly See Note 2 E8 Abnormal Gear Motor Amperage FM 481 only Gear Motor Amperage Sensor is ...

Page 23: ... FM 481 All Code Error Condition Operation Reset Check Repair CM Time Microcomputer Read Write Error Microcomputer fails to read write properly Memory circuit not available Replace Controller Board Error records and compressor operating hours not available on display c1 Low Water Water supply continues for more than 90 seconds or Float Switch trips at lower float level and does not reset for more ...

Page 24: ...0 minutes 5 accuracy Main Controller Board Drawing Nos and Dip Switch Setting Dip Switch Drawing No 1 2 3 4 5 6 Factory Inspection Marking Applicable Models 459866 04 459866 14 ON ON OFF OFF ON OFF H9 Modular type with Rotation Sensor FM 481 etc 459866 06 459866 16 ON ON OFF ON ON OFF Hb Modular type FM 1000ASFE3 etc 459866 07 459866 17 OFF ON OFF ON ON OFF Fb Self contained type CM 100 etc 459866...

Page 25: ...ALGE ON ON OFF OFF ON OFF FM 1000ASFE3 FM 1000ALE FM 1000ALF FM 2000ALE FM 2000ALF ON ON OFF ON ON OFF FM 1000ASFE3 K 1 K 2 A 0 ON ON ON ON ON OFF CM 110FE FM 120FE OFF ON OFF ON OFF OFF Dip Switch Setting GENERAL OCEANIA A 1 and after Dip Switch Model 1 2 3 4 5 6 CM 230AF FM 250AF ON ON OFF ON ON OFF FM 481AG FM 481AWG ON ON OFF OFF ON OFF CM 100F FM 120F OFF ON OFF ON OFF OFF 22 E2AH5820209 ...

Page 26: ...ppliance is not suitable for installation in an area where a water jet could be used and where dripping is not allowed could be used and where dripping is not allowed 6 Do not place anything on top of the icemaker or in front of the Louver 6 Do not place anything on top of the icemaker or in front of the Louver 2 ELECTRICAL CONNECTIONS 2 ELECTRICAL CONNECTIONS WARNING WARNING THIS APPLIANCE MUST B...

Page 27: ... ensure drain pipe has an adequate pitch or fall The icemaker drain is gravity flow so ensure drain pipe has an adequate pitch or fall Water should drain into an open trap Water should drain into an open trap On water cooled model a back flow preventer may be required in the cooling water circuit On water cooled model a back flow preventer may be required in the cooling water circuit 1 Water Coole...

Page 28: ...s These pipes can be cut to length as necessary to suit position of main drain necessary to suit position of main drain Note Note On water cooled model make the On water cooled model make the same connection to free end of 3 4 same connection to free end of 3 4 3 8 nipple on the condenser outlet 3 8 nipple on the condenser outlet Water Supply Tap Water Supply Tap Inlet Hose Inlet Hose Fig 3 Fig 3 ...

Page 29: ...ed in the trial run It might be contaminated with foreign matter in the water circuit Discard or flush down the drain matter in the water circuit Discard or flush down the drain 3 Clean the Storage Bin before use see III 1 CLEANING in Instruction 3 Clean the Storage Bin before use see III 1 CLEANING in Instruction Manual Manual Control Box Control Box Operation Operation Switch Switch Motor Motor ...

Page 30: ...d be checked for wear after a total of 8 000 10 000 hour operation from installation date for wear after a total of 8 000 10 000 hour operation from installation date Note Note The clearance between the Auger blades and the Evaporator interior is 0 4 0 5 mm 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 l...

Page 31: ...g on the location of the icemaker 5 AIR FILTER AIR COOLED MODEL ONLY 5 AIR FILTER AIR COOLED MODEL ONLY A plastic mesh Air Filter removes dirt or dust from the air and keeps the Condenser from A plastic mesh Air Filter removes dirt or dust from the air and keeps the Condenser from getting clogged As the Filter gets clogged the icemaker s performance will be reduced getting clogged As the Filter ge...

Page 32: ... from the Water Valve 4 Remove the Mesh Filter from the Water Valve 5 Clean the Mesh using a brush 5 Clean the Mesh using a brush 6 Replace the Mesh and Inlet Hose in their correct positions 6 Replace the Mesh and Inlet Hose in their correct positions 7 Open the water supply tap 7 Open the water supply tap 8 Connect the power source 8 Connect the power source 9 Check for leaks 9 Check for leaks Fi...

Page 33: ...tiser immediately 6 Wipe off any splashed or spilt cleaner sanitiser immediately 7 Do not use any ammonia type cleaners on any part of the icemaker 7 Do not use any ammonia type cleaners on any part of the icemaker STEP 1 STEP 1 Dilute the solutions with water as follows Dilute the solutions with water as follows Cleaning solution Cleaning solution Nickel Safe Ice Machine Cleaner by The Rectorseal...

Page 34: ...pen the Access Flap and press the Stop Button 12 Allow time for the Gear Motor to stop and the water system to drain 12 Allow time for the Gear Motor to stop and the water system to drain 13 Unplug the icemaker 13 Unplug the icemaker 14 Refit the Top and Front Panels Plug in the icemaker 14 Refit the Top and Front Panels Plug in the icemaker 15 Allow the icemaker to make ice for approximately 10 m...

Page 35: ... water 3 Mix 5 litres of water with 18 mL of 5 25 sodium hypochlorite solution in a suitable container 3 Mix 5 litres of water with 18 mL of 5 25 sodium hypochlorite solution in a suitable container or the recommended Hoshizaki sanitiser as directed or the recommended Hoshizaki sanitiser as directed 4 Soak a clean sponge or cloth with the solution and wipe all the surfaces of the Bin Liner Ice 4 S...

Page 36: ...ON V TECHNICAL INFORMATION 1 WATER AND REFRIGERANT CIRCUIT 1 WATER AND REFRIGERANT CIRCUIT a FM 481AGE FM 481AGE N a FM 481AGE FM 481AGE N Pressure Switch Pressure Switch Cut out Cut out 28 5 1 5 0 bar 28 5 1 5 0 bar Cut in Cut in 23 1 5 bar 23 1 5 bar ...

Page 37: ...34 34 E2AH5820209 E2AH5820209 b FM 481AWGE FM 481AWGE N b FM 481AWGE FM 481AWGE N Pressure Switch Pressure Switch Cut out Cut out 22 1 5 0 bar 22 1 5 0 bar Cut in Cut in 18 1 5 bar 18 1 5 bar ...

Page 38: ...35 35 E2AH5820209 E2AH5820209 2 WIRING DIAGRAM 2 WIRING DIAGRAM ...

Page 39: ...illuminated on the Display the water supply When the Stop Button is pressed with ICE illuminated on the Display the water supply cycle continues until the Gear Motor stops and the Display stops illuminating ICE and cycle continues until the Gear Motor stops and the Display stops illuminating ICE and starts blinking STOP starts blinking STOP 2 2 When the Stop Button is pressed the Compressor stops ...

Page 40: ...s in 5 minutes The Compressor stops and the Gear Motor stops in 5 minutes 4 4 After the Gear Motor stops the Control Water Valve stays open until the Float Switch trips After the Gear Motor stops the Control Water Valve stays open until the Float Switch trips at the upper water level Then the Control Water Valve closes and the Flush Water Valve at the upper water level Then the Control Water Valve...

Page 41: ...eeps on illuminating ICE time The Display keeps on illuminating ICE 3 3 If the Bin Control Switch resets in less than 60 minutes the icemaker starts the process of If the Bin Control Switch resets in less than 60 minutes the icemaker starts the process of a STARTUP ICEMAKING OPERATION a STARTUP ICEMAKING OPERATION Fig 8 Fig 8 Float Switch FS Float Switch FS Bin Control Switch S1 Bin Control Switch...

Page 42: ...r level The Control Water Valve stays open until the Float Switch trips at the upper water level Then the Control Water Valve closes and the Flush Water Valve opens for 10 minutes Then the Control Water Valve closes and the Flush Water Valve opens for 10 minutes 4 4 When the Flush Water Valve closes after 10 minutes the Display illumination changes When the Flush Water Valve closes after 10 minute...

Page 43: ... operated for some unidentified reason be sure to check Gear Motor Circuit Protector has operated for some unidentified reason be sure to check the Actuator for proper dimensions the Actuator for proper dimensions 1 Remove the Bin Control Switch from the Chute 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 2 Move ...

Page 44: ...pen to stop the icemaker error code EL contacts open to stop the icemaker error code EL To restart the icemaker remove ice from the Spout and Chute and move the Operation To restart the icemaker remove ice from the Spout and Chute and move the Operation Switch to the STOP position then to the RUN position Switch to the STOP position then to the RUN position Spout Spout Fig 11 Fig 11 Spout Spout Ba...

Page 45: ...Water Temp C Water Consumption m 3 day 0 100 200 300 400 500 600 10 10 21 15 32 21 Ambient Temp Water Temp C Ice Production Capacity kg day Ice Production Capacity kg day 10 10 10 12 14 16 18 20 22 10 10 21 15 32 21 Ambient Temp Water Temp C Head Pressure bar 1 6 1 8 2 2 2 2 4 2 6 2 8 Suction Pressure bar Head Pressure bar Suction Pressure bar ...

Page 46: ...r Consumption m 3 day 0 100 200 300 400 500 600 10 10 21 15 32 21 Ambient Temp Water Temp C Ice Production Capacity kg day Ice Production Capacity kg day 10 10 10 12 14 16 18 20 22 10 10 21 15 32 21 Ambient Temp Water Temp C Head Pressure bar 1 6 1 8 2 2 2 2 4 2 6 2 8 Suction Pressure bar Head Pressure bar Suction Pressure bar ...

Page 47: ...ion m 3 day 0 100 200 300 400 500 600 10 10 21 15 32 21 Ambient Temp Water Temp C Ice Production Capacity kg day Ice Production Capacity kg day 10 10 10 12 14 16 18 20 22 10 10 21 15 32 21 Ambient Temp Water Temp C Head Pressure bar 1 60 1 80 2 00 2 20 2 40 2 60 2 80 Suction Pressure bar Head Pressure bar Suction Pressure bar ...

Page 48: ...ption m 3 day 0 100 200 300 400 500 600 10 10 21 15 32 21 Ambient Temp Water Temp C Ice Production Capacity kg day Ice Production Capacity kg day 10 10 10 12 14 16 18 20 22 10 10 21 15 32 21 Ambient Temp Water Temp C Head Pressure bar 1 60 1 80 2 00 2 20 2 40 2 60 2 80 Suction Pressure bar Head Pressure bar Suction Pressure bar ...

Page 49: ...f ice production the pressure gauge should read 18 bar or the thermometer 2 After 5 minutes of ice production the pressure gauge should read 18 bar or the thermometer read 38 40 C If the readings are lower use a flat blade screwdriver to adjust the screw read 38 40 C If the readings are lower use a flat blade screwdriver to adjust the screw in a clockwise direction If the readings are higher adjus...

Page 50: ...uity and replace e Transformer 1 Coil winding opened 1 Replace f Water Valve 1 Coil winding opened 1 Replace 1 Closed 1 Open g Water Supply Tap 2 Water failure 2 Wait till water is supplied 1 Disconnected 1 Connect h Plug and Receptacle Control Box 2 Terminal out of Plug or Receptacle 2 Insert Terminal back in position 1 The icemaker will not start i Chute Switch 1 Tripped 1 See V 3 g CHUTE SWITCH...

Page 51: ...r components plugged 5 Clean and replace Drier 6 Bad contacts 6 Check for continuity and replace 3 Continued f Pressure Switch 7 Loose connections 7 Tighten 1 Bad contacts 1 Check for continuity and replace Controller Board a X2 Relay on Controller Board 2 Coil winding opened 2 Replace Controller Board b Thermal Relay 1 Tripped 1 Reset 1 Loose connections 1 Tighten 2 Motor winding opened or earthe...

Page 52: ...eplace 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 broken 1 Replace b Compressor 2 Mounting pad out of position 2 Reinstall c Refrigerant Lines 1 Rub or touch lines or other surfaces 1 Replace d Gear Motor Ice Making 1 Bearing ...

Page 53: ...iaphragm does not close 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 50 E2DA5810209 ...

Page 54: ...t needs brazing It is no problem to use the same handy flux Repair of the refrigerant circuit needs brazing It is no problem to use the same handy flux that has been used for the current refrigerants However its entrance into the refrigerant that has been used for the current refrigerants However its entrance into the refrigerant circuit should be avoided as much as possible circuit should be avoi...

Page 55: ... side Access Valve for ease When replacing the Drier take the opportunity to also fit a High side Access Valve for ease of charging liquid refrigerant of charging liquid refrigerant c EVACUATION AND RECHARGE c EVACUATION AND RECHARGE 1 Attach Charging Hoses Service Manifold and Vacuum Pump to the Low side and High 1 Attach Charging Hoses Service Manifold and Vacuum Pump to the Low side and High si...

Page 56: ...ging large quantities of liquid into the low side in case of damage to the Compressor Compressor Fig 13 Fig 13 Cap Cap Access Valve Access Valve Depressed Depressed OPEN OPEN 2 BRAZING 2 BRAZING DANGER DANGER 1 Refrigerant R404A itself is not flammable explosive and poisonous However 1 Refrigerant R404A itself is not flammable explosive and poisonous However when exposed to an open flame R404A cre...

Page 57: ...n repairing a refrigerant system be careful not to let the burner flame contact any electrical wires or insulation any electrical wires or insulation 6 Remove the Bolts and Rubber Grommets 6 Remove the Bolts and Rubber Grommets 7 Slide and remove the Compressor Unpack the new Compressor package Install the 7 Slide and remove the Compressor Unpack the new Compressor package Install the new Compress...

Page 58: ...source 2 Remove the Front Panel 2 Remove the Front Panel 3 Recover the refrigerant and store it in a proper container if required by an applicable law 3 Recover the refrigerant and store it in a proper container if required by an applicable law See 1 b REFRIGERANT RECOVERY See 1 b REFRIGERANT RECOVERY 4 Remove the Drier using brazing equipment 4 Remove the Drier using brazing equipment 5 Install t...

Page 59: ...azing equipment equipment 6 Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 0 2 0 3 bar 6 Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 0 2 0 3 bar WARNING WARNING Always protect the valve body by using a damp cloth to prevent the valve from Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze...

Page 60: ...nt 6 Disconnect the Flare connections of the valve 6 Disconnect the Flare connections of the valve 7 Remove the screws and the valve from the Bracket 7 Remove the screws and the valve from the Bracket 8 Install the new valve and braze the Capillary Tube 8 Install the new valve and braze the Capillary Tube 9 Install the new Drier 9 Install the new Drier 10 Check for leaks using nitrogen gas 10 bar ...

Page 61: ...rews and lift off the Extruding Head 9 Remove the three Socket Head Cap Screws and lift off the Extruding Head 10 Check the Bearing inside the Extruding Head If it is worn out or scratched replace the 10 Check the Bearing inside the Extruding Head If it is worn out or scratched replace the Bearing Bearing Note Replacing the Bearing needs a fitting tool If it is not available replace the whole Note...

Page 62: ...connect the three Hoses from the Evaporator 17 Remove the four Socket Head Cap Screws securing the Evaporator with the Bearing 17 Remove the four Socket Head Cap Screws securing the Evaporator with the Bearing Lower Lower 18 Lift off the Evaporator 18 Lift off the Evaporator BEARING LOWER AND MECHANICAL SEAL BEARING LOWER AND MECHANICAL SEAL 19 The Mechanical Seal consists of two parts One part ro...

Page 63: ...cratchnortocontaminateitscontact surface surface 25 When replacing the Evaporator 25 When replacing the Evaporator a Braze the new Evaporator with nitrogen gas flowing at the pressure of 0 2 0 3 bar a Braze the new Evaporator with nitrogen gas flowing at the pressure of 0 2 0 3 bar b Replace the Drier b Replace the Drier c Check for leaks using nitrogen gas 10 bar and soap bubbles c Check for leak...

Page 64: ...tor Cover Socket Head Socket Head Cap Screw Cap Screw Belt Heater Belt Heater Evaporator Evaporator Rubber Rubber O ring O ring Nylon Nylon Ring Ring Bolt Bolt Cutter Cutter Extruding Extruding Head Head Gear Motor Gear Motor O ring O ring Housing Housing Coupling Coupling Spline Spline Flake Flake Nugget Nugget ...

Page 65: ...alve Inlets and remove the Control Water 6 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 Valve Do not lose the Packings inside the Fitting Nut 7 Install the new Control Water Valve 7 Install the new Control Water Valve 8 Assemble the removed parts in the reverse order of which they were removed 8 Assemble...

Page 66: ...Valve from the Bracket 7 Remove the Drain Pipe from the Flush Water Valve 7 Remove the Drain Pipe from the Flush Water Valve 8 Connect the Drain Pipe to the new Flush Water Valve and place the valve in position 8 Connect the Drain Pipe to the new Flush Water Valve and place the valve in position 9 Connect the Hose to the Flush Water Valve and secure it with the Clamp 9 Connect the Hose to the Flus...

Page 67: ... Board referring to the Instruction Sheet attached See II 2 2 Modify the Service Board referring to the Instruction Sheet attached See II 2 CONTROLLER BOARD for the Dip Switch setting CONTROLLER BOARD for the Dip Switch setting b REPLACEMENT b REPLACEMENT 1 Disconnect the power source 1 Disconnect the power source 2 Remove the Front Panel 2 Remove the Front Panel 3 Remove screws and the Control Bo...

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