Hoshizaki FD-1002MAJ-C Manual

Hoshizaki Ismaskine FD-1002MAJ-C

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Models
H and J Series
Modular Flaker with
F-A and F-C Control Boards
Service Manual
Number: 73204
Issued: 7-23-2014
Revised: 9-21-2016
hoshizakiamerica.com
2
WARNING
Only qualied service technicians should install and service the appliance. To
obtain the name and phone number of your local Hoshizaki Certied Service
Representative, visit www.hoshizaki.com. No service should be undertaken until
the technician has thoroughly read this Service Manual. Failure to service and
maintain the appliance in accordance with this manual will adversely affect safety,
performance, component life, and warranty coverage and may result in costly water
damage. Proper installation is the responsibility of the installer. Product failure or
property damage due to improper installation is not covered under warranty.
Hoshizaki provides this manual primarily to assist qualied service technicians in the
service of the appliance.
Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call, send an e-mail message, or write to the Hoshizaki Technical
Support Department for assistance.
Phone: 1-800-233-1940; (770) 487-2331
Fax: 1-800-843-1056; (770) 487-3360
E-mail: techsupport@hoshizaki.com
618 Highway 74 South
Peachtree City, GA 30269
Attn: Hoshizaki Technical Support Department
Web Site: www.hoshizaki.com
NOTE: To expedite assistance, all correspondence/communication MUST include the
following information:
• Model Number
• Serial Number
• Complete and detailed explanation of the problem.
3
CONTENTS
Important Safety Information 6 .................................................................................................
I. Construction and Water/Refrigeration Circuit Diagram 8 .......................................................
A. Construction 8 ..................................................................................................................
1. Air-Cooled Models .................................................................................................... 8
2. Water-Cooled Models ............................................................................................. 9
3. Remote Air-Cooled Models .................................................................................... 10
4. Low-Side, Parallel Rack System Models ................................................................11
B. Icemaking Unit ............................................................................................................ 12
C. Water/Refrigeration Circuit Diagram ............................................................................ 13
1. Air-Cooled Models .................................................................................................. 13
2. Water-Cooled Models ............................................................................................ 14
3. Remote Air-Cooled Models .................................................................................... 15
4. Low-Side, Parallel Rack System Models ............................................................... 16
II. Sequence of Operation and Service Diagnosis ............................................................... 17
A. Sequence of Operation Flow Chart ............................................................................. 17
1. Icemaking and Drain Cycle .................................................................................... 17
2. Shutdown .............................................................................................................. 18
B. Service Diagnosis ....................................................................................................... 19
C. Control Board Check 25 ...................................................................................................
D. Bin Control Check 30 .......................................................................................................
E. Float Switch Check and Cleaning 34 ...............................................................................
F. Diagnostic Tables ......................................................................................................... 36
III. Controls and Adjustments 39 ...............................................................................................
A. Control Board 39 ..............................................................................................................
1. Control Board Layout 40 .............................................................................................
2. LED Lights and Audible Alarm Safeties 41 .................................................................
3. Ice Purge Cycle Bypass 42 .........................................................................................
B. Controls and Adjustments 42 ...........................................................................................
1. Default Dip Switch Settings 42 ....................................................................................
2. BC1 (Infrared Sensor) Shutdown Delay (S1 dip switch 1, 2, 3) 43 .............................
3. Drain Frequency Control (S1 dip switch 4) 43 ............................................................
4. Continuous Dispensing Timer (S1 dip switch 5 & 6) 43 ..............................................
5. Bin Control Selector (S1 dip switch 7) 44 ...................................................................
6. BC(2) (Mech. Stand-Alone or Backup (only)) Shutdown Delay (S1 dip switch 8) 44 ..
7. Factory Use (S1 Dip Switch 9 & 10) 44 .......................................................................
C. Power Switch and Control Switch 45 ................................................................................
IV. Refrigeration Circuit and Component Service Information.............................................. 46
A. Refrigeration Circuit Service Information 46 ....................................................................
B. Component Service Information 49 ..................................................................................
IMPORTANT
This manual should be read carefully before the appliance is serviced. Read
the warnings and guidelines contained in this manual carefully as they provide
essential information for the continued safe use, service, and maintenance of the
appliance. Retain this manual for any further reference that may be necessary.
4
V. Maintenance 56 ....................................................................................................................
VI. Disposal 58 ..........................................................................................................................
VII. Technical Information ..................................................................................................... 59
A. Specication & Performance Data Sheets 59 ..................................................................
1a. F-1001MAH 59 ..........................................................................................................
1b. F-1001MAH-C 60 ......................................................................................................
2a. F-1001MWH 61 .........................................................................................................
2b. F-1001MWH-C 62 .....................................................................................................
3a. F-1001MRH 63 ..........................................................................................................
3b. F-1001MRH-C 64 ......................................................................................................
4a. F-1501MAH 65 ..........................................................................................................
4b. F-1501MAH-C 66 .....................................................................................................
5a. F-1501MWH 67 .........................................................................................................
5b. F-1501MWH-C 68 .....................................................................................................
6a. F-1501MRH.......................................................................................................... 69
6b. F-1501MRH-C 70 ......................................................................................................
7. F-2001MWH 71 ...........................................................................................................
8a. F-2001MRH 72 .........................................................................................................
8b. F-2001MRH-C 73 ......................................................................................................
8c. F-2001MRH3 .........................................................................................................74
9. F-2001MLH 75 ............................................................................................................
10. FD-650MAH-C ..................................................................................................... 76
11. FD-650MWH-C 77 .....................................................................................................
12. FD-650MRH-C 78 .....................................................................................................
13. FD-1001MAH-C 79 ...................................................................................................
14. FD-1001MRH-C 80 ...................................................................................................
15a. F-450MAJ 81 ..........................................................................................................
15b. F-450MAJ-C 82 .......................................................................................................
16a. F-801MAJ........................................................................................................... 83
16b. F-801MAJ-C 84 .......................................................................................................
17a. F-801MWJ.......................................................................................................... 85
17b. F-801MWJ-C 86 ......................................................................................................
18a. F-1001MAJ 87 .........................................................................................................
18b. F-1001MAJ-C 88 .....................................................................................................
19a. F-1001MWJ 89 ........................................................................................................
19b. F-1001MWJ-C 90 ....................................................................................................
20a. F-1001MRJ 91 ........................................................................................................
20b. F-1001MRJ-C 92 .....................................................................................................
21a. F-1001MLJ 93 .........................................................................................................
21b. F-1002MLJ 94 .........................................................................................................
22a. F-1002MAJ 95 ........................................................................................................
22b. F-1002MAJ-C 96 .....................................................................................................
23a. F-1002MWJ 97 .......................................................................................................
23b. F-1002MWJ-C 98 ....................................................................................................
24a. F-1002MRJ 99 ........................................................................................................
24b. F-1002MRJ-C .................................................................................................. 100
5
25a. F-1501MAJ........................................................................................................101
25b. F-1501MAJ-C ................................................................................................... 102
26a. F-1501MWJ...................................................................................................... 103
26b. F-1501MWJ-C .................................................................................................. 104
27a. F-1501MRJ ...................................................................................................... 105
27b. F-1501MRJ-C ................................................................................................... 106
28. FD-1001MAJ-C .................................................................................................. 107
29. FD-1001MRJ-C .................................................................................................. 108
30. FD-1002MAJ-C .................................................................................................. 109
31. FD-1002MRJ-C ...................................................................................................110
B. Wiring Diagrams ......................................................................................................... 111
1. F-1001MAH(-C), F-1001MWH(-C), F-1001MRH(-C), FD-1001M_H-C ................... 111
2. F-1501M_H(-C) .....................................................................................................112
3. F-2001MWH(-C), F-2001MRH(-C)(3),F-2001MWJ(-C), F-2001MRJ(-C)(3) ..........113
4. F-2001MLH, F-1001MLJ, F-1002MLJ, F-2001MLJ ................................................114
5. FD-650M_H-C ......................................................................................................115
6. F-450MAJ(-C) .......................................................................................................116
7. F-801M_J(-C) ........................................................................................................117
8. F-1001MAJ(-C), F-1001MWJ(-C), F-1001MRJ(-C) ................................................118
9. F-1002MAJ(-C), F-1002MWJ(-C), F-1002MRJ(-C), FD-1002M_J-C .....................119
10. F-1501M_J(-C) ................................................................................................... 120
11. FD-1001M_J-C ................................................................................................... 121
6
Important Safety Information
Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, damage to the appliance, or damage to property.
WARNING Indicates a hazardous situation which could result in death or
serious injury.
NOTICE Indicates a situation which could result in damage to the
appliance or property.
IMPORTANT Indicates important information about the installation, use, and
care of the appliance.
WARNING
The appliance should be destined only to the use for which it has been expressly
conceived. Any other use should be considered improper and therefore dangerous.
The manufacturer cannot be held responsible for injury or damage resulting
from improper, incorrect, and unreasonable use. Failure to install, operate, and
maintain the appliance in accordance with this manual will adversely affect safety,
performance, component life, and warranty coverage and may result in costly water
damage.
To reduce the risk of death, electric shock, serious injury, or re, follow basic
precautions including the following:
• Only qualied service technicians should install and service the appliance.
• The appliance must be installed in accordance with applicable national, state, and
local codes and regulations.
• Electrical connection must be hard-wired and must meet national, state, and local
electrical code requirements. Failure to meet these code requirements could result
in death, electric shock, serious injury, re, or damage.
• The icemaker requires an independent power supply of proper capacity. See the
nameplate for electrical specications. Failure to use an independent power supply
of proper capacity can result in a tripped breaker, blown fuse, damage to existing
wiring, or component failure. This could lead to heat generation or re.
• THE ICEMAKER MUST BE GROUNDED. Failure to properly ground the icemaker
could result in death or serious injury.
• To reduce the risk of electric shock, do not touch the power switch or control switch
with damp hands.
• Move the power switch to the "OFF" position and turn off the power supply before
servicing. Lockout/Tagout to prevent the power supply from being turned back on
inadvertently.
• Do not place ngers or any other objects into the ice discharge opening.
• Do not make any alterations to the appliance. Alterations could result in electric
shock, injury, re, or damage.
8
I. Construction and Water/Refrigeration Circuit Diagram
A. Construction
1. Air-Cooled Models
Model Shown: F-1501MAH
Inlet Water Valve
Reservoir Bin Control 2
(Mechanical)
(If Applicable)
Spout
Evaporator
Gear Motor
Compressor
Drain Valve
Fan Motor
Ice Chute
Junction Box
Float Switch
High-Pressure Switch
Condenser
Bin Control 1
(Infrared Sensor)
Thermostatic
Expansion Valve
Control Switch
Power Switch
Drier
Water Supply Inlet
Drip Pan
Evaporator
Heater (-C)
10
3. Remote Air-Cooled Models
Model Shown: F-1001MRH-C
Inlet Water Valve
Reservoir
Spout
Evaporator
Gear Motor Compressor
Drain Valve
Evaporator
Heater (-C)
Float Switch
Junction Box
Thermostatic
Expansion Valve
Ice Chute
High-Pressure Switch
Drier
Water Supply Inlet
Crankcase
Heater
Reciever
Power Switch
Control Switch
Drip Pan
Model Shown: F-1001MRJ-C
Inlet Water Valve
Reservoir
Bin Control
(Infrared Sensor)
Spout
Evaporator
Gear Motor
Compressor
Drain Valve
Evaporator
Heater (-C)
Float Switch
Junction Box
Thermostatic
Expansion Valve
Ice Chute
High-Pressure Switch
Drier
Water Supply Inlet
Crankcase
Heater
Reciever
Power Switch
Control Switch
Drip Pan
Bin Control 2
(Mechanical)
(If Applicable)
12
B. Icemaking Unit
Model Shown: F-1501MAH
Seal Bolt
Gear Motor
Spline Coupling
Lower Housing
O-Ring
Mechanical-Seal
Cylinder
Auger
Extruding Head-Upper Bearing
Cutter
Insulation
Socket Head Cap Screw
with Split Lock Washer
Hex Bolt and Washer
Evaporator Heater (-C Models)
Drip Pan
13
C. Water/Refrigeration Circuit Diagram
1. Air-Cooled Models
Drier
Condenser
Condenser
Fan Motor
High Pressure
Switch
Compressor
Overow
Reservoir
Drain
Valve
Thermostatic
Expansion Valve
Spout
Water Level
Evaporator
Float
Switch
Inlet Water Valve
Water Supply
Line
Gear Motor Drain Pan
Drain Outlet
Insulation
Evaporator Condensate
Drain Pan (Drip Pan)
Gear Motor
Drain Hose
14
2. Water-Cooled Models
Water Supply
Line
Water Supply Line
Drain Outlet
Condenser
Water Regulating Valve
Drier
Thermostatic
Expansion Valve
Insulation
Evaporator Condensate
Drain Pan (Drip Pan)
Spout
Float
Switch
Inlet Water Valve
Reservoir
Water Level
Evaporator
Overow
Drain
Valve
Gear Motor
Drain Outlet
Gear Motor Drain Pan
High-Pressure
Switch
Compressor
Drain Hose
15
3. Remote Air-Cooled Models
Drier
Remote Condenser
Condenser Fan Motor
High-Pressure
Switch
Compressor
Overow
Reservoir
Drain
Valve
Thermostatic
Expansion Valve
Spout
Water Level
Evaporator
Float
Switch
Inlet Water Valve
Water Supply
Line
Gear Motor Drain Pan
Drain Outlet
Insulation
Evaporator Condensate
Drain Pan (Drip Pan)
Gear Motor
Drain Hose
16
4. Low-Side, Parallel Rack System Models
Overow
Reservoir
Drain
Valve
Thermostatic
Expansion Valve
Spout
Water Level
Evaporator
Float
Switch
Inlet Water Valve
Water Supply
Line
Gear Motor Drain Pan
Drain Outlet
Insulation
Evaporator Condensate
Drain Pan (Drip Pan)
Gear Motor
Liquid Line Valve
Suction Line Valve
Evaporator Pressure Regulator (EPR Valve)
From Rack System
To Rack System
Drain Hose
NOTICE! F-1001MLH Use only with R-404A
F-1002MLJ Use only with R-404A, R-407A, or R-407F
EPR Settings:
F-1001MLH: R-404A EPR Setting: 31 PSIG
F-1002MLJ: R-404A EPR Setting: 31 PSIG
R-407A EPR Setting: 22 PSIG
R-407F EPR Setting: 23 PSIG
17
II. Sequence of Operation and Service Diagnosis
A. Sequence of Operation Flow Chart
1. Icemaking and Drain Cycle
1-in-1 drain cycle. DV opens for 2 sec. every hour
(CB S1 Dip Switch 4).
Icemaker status does not change.
Control Board Sequence of Operation Flow Chart - Icemaking and Drain Cycle
LFS closed
UFS closed
FZT starts
FT terminated
WV de-energized
3. 1-in-12 Drain Cycle
& Restart (optional)
UFS open
LFS open (WV on)
FT starts (90 sec.)
FZT terminated
WV energized
Comp continues
GM continues
FM continues
FMR continues
LLV continues
SLV continues
1. Startup
2. Ice Purge Cycle
WV energized
Comp energized
LLV energized
SLV energized
GM continues
FM continues
FMR continues
2. 1-in-1 Drain Cycle
Comp de-energized
LLV de-energized
SLV de-energized
GM continues
FM continues
FMR continues
1. Fill Cycle 3. Freeze Cycle
LFS closed
UFS closed
FZT starts (30
min.)
FT terminated
WV de-energized
Comp continues
GM continues
FM continues
FMR continues
LLV continues
SLV continues
Low Water Safety
Purge Timer
UFS open
WV energized
Comp de-energized
LLV de-energized
SLV de-energized
GM continues
FM continues
FMR continues
DV energized
GM de-energized
FM de-energized
FMR de-energized
10-min. DT terminated
DV de-energized
1-in-12 DT reset
5 min.
4. Icemaker Restart 2 Ice Purge Cycle.3 10-Min. Drain.
If Fil > 90 sec. l FT
1-beep alarm sounds
WV continues
When UFS closes
alarm resets and
2. Ice Purge Cycle starts.
FT Maximum
90 sec.
4. 1-in-12 Drain Cycle - Although the factory default 1-in-1 drain cycle
is recommended, a 1-in-12 drain cycle is available. For 1-in-12 drain
cycle sequence, see "3. 1-in-12 Hour Drain Cycle & Restart (optional)."
Rell
FT Maximum
90 sec.
90 sec. exceeded, FT
90 sec. starts and PT
1-beep alarm sounds
90. sec. PT terminates
unit shuts down and
1-beep alarm continues.
When UFS closes, alarm
resets and 2. Ice Purge
Cycle starts.
WV continues
GM de-energized
FM de-energized
FMR de-energized
1 DT Initiates DC.
To bypass, press the
"SERVICE" button after
GM starts.
5 min.
to "1. Fill Cycle" above
90 sec.
(CB S1 dip switch 4 "ON")
FT off (90 sec.)
5 or 30 sec.
(S1 Dip Switch 7)
EH energized
GM energized
FM energized
FMR energized
1 DT Initiates DC.
Continued uninterrupted
operation
DV energizes for 2 sec.
2 Continued Operation.
DV de-energizes, no
interruption in ice production
30-min. FZT
Startup FZT exceeded (LFS does not
open): CB shuts down icemaker
and sounds a 5-beep alarm.
Legend:
BC-bin control (mechanical stand-alone)
BC1-bin control 1 (infrared sensor)
BC2-bin control 2 (mechanical backup)
CB-control board
Comp-compressor
DC-drain cycle
DT-drain timer
DV-drain valve
EH-evaporator heater
FM-fan motor
FMR-fan motor-remote
FT-ll timer (low water safety)
FZT-freeze timer
GM-gear motor
LFS-lower oat switch
LLV-liquid line valve (MLH)
PT-purge timer
SLV-suction line valve (MLH)
UFS-upper oat switch
WV-inlet water valve
Low Water Safety
Shutdown
(CB S1 dip switch 4 "OFF")
Normal Operation
Power Switch "ON"
Control Switch in "ICE"
POWER OK LED on
BC1 Green LED on
BC1 Yellow LED off
BC(2) Closed
25
C. Control Board Check
Before replacing a control board that does not show a visible defect and that you suspect
is bad, always conduct the following check procedure. This procedure will help you verify
your diagnosis.
1) Check CB S1 dip switch settings to assure that they are in the factory default position.
For factory default settings, see "III.B.1. Default Dip Switch Settings."
Note: S1 dip switch 7determines bin control application:
BC (mechanical stand-alone) or BC2 (mechanical backup only): S1 dip switch 7 in
the "OFF" position.
BC1 (infrared sensor stand-alone) or with BC2 (mechanical backup): S1 dip switch
7in the "ON" position.
2) Move the power switch to the "ON" position and move the control switch to the "ICE"
position. The "POWER OK" LED turns on. Diagnosis "POWER OK" LED: Check that
the CB "POWER OK" LED is on. If not, check for proper supply voltage (115VAC) input
to the control transformer (power switch, breaker, and fuse). Next, check for proper
low-voltage (24VAC) output from the control transformer and that the 1A fuse is good.
Check for 24VAC at CB K8 #1 (W/R) to CB K8 #2 (LBU). If 24VAC is present and the
"POWER OK" LED is off, replace CB.
3) BC1 (infrared sensor) Power Supply (K6 connector): CB supplies 20VDC to BC1
and BC1 green LED is on. Check that BC1 green LED is on. If not, check Diagnosis:
for 20VDC between CB K6 #1 (DBU) and CB K6 #3(BR). See Fig. 1. If 20VDC is not
present, replace CB. If 20VDC is present, conrm that the yellow LED is not ashing
or steady. If BC1 yellow LED is on or ashing, move ice away from lens. If no ice is
present, clean the lens with a warm, clean damp cloth. If cleaning the lens does not
work, replace BC1 (infrared sensor).
Fig. 1
Red Positive
Test Lead
Black Negative
Test Lead
20VDC
Multimeter
3
2
1
K6 #3
Brown (BR)
K6 #2
White (W)
K6 #1
Dark Blue (DBU)
• K6 Connector
BC1 (Infrared Sensor)
BC1 (infrared sensor) (20VDC)
Open (yellow LED ashing or steady)
20VDC K6 #1 (DBU) to K6 #3 (BR)
0VDC K6 #1 (DBU) to K6 #2 (W)
20VDC K6 #2 (W) to K6 #3 (BR)
BC1 (infrared sensor) (20VDC) Closed
20VDC K6 #1 (DBU) to K6 #3 (BR)
20VDC K6 #1 (DBU) to K6 #2 (W)
0VDC K6 #2 (W) to K6 #3 (BR)
27
c) Compressor Control Relay/Gear Motor Protect Relay (CCR/GMPR) –
CB K9 #5(W/O) and CB K9 #6 (W/O): 5VDC is present from CB white K5 connector,
pin closest to CB red K4 connector to CB K9 #5 (W/O) at all times. If 5VDC is not
present, replace CB. When CCR/GMPR terminals #3 (W/O) and #4 (W/O) are open
(CCR/GMPR de-energized), 5VDC is present between CB K9 #5 (W/O) and CB K9
#6 (W/O). When CCR/GMPR terminals #3(W/O) and #4 (W/O) are closed (CCR/
GMPR energized), 5VDC is present between CB K9 #5 (W/O) and CB K9 #6 (W/O).
When CCR/GMPR terminals #3 (W/O) & #5 (W/O) are open CB may be in an
8-beep alarm. See "III.A.2. LED Lights and Audible Alarm Safeties."
d) Bin Control (2) (mechanical stand-alone or backup) –
CB K8 #3 (GY) and CB K8 #4(GY): 5VDC is present from CB white K5 connector,
pin closest to CB red K4 connector to CB K8 #3 (GY) at all times. If 5VDC is not
present, replace CB. When BC(2) is closed (calling for ice), 5VDC is present from
CB white K5 connector, pin closest to CB red K4 connector, to CB K8 #3 (GY) and
CB K8 #4(GY). If 5VDC is not present to either CB K8 #3 (GY) or CB K8 #4(GY),
replace CB. If 5VDC is present at CB K8 #3 (GY) and not to CB K8 #4 (GY), BC(2) is
open. See "II.D.2. Bin Control (2) (mechanical stand-alone or backup) Check."
e) Float Switch (LFS and UFS) – CB K8 #5 (BK) (common), CB K8 #6(R) (upper),
and CB K8 #7 (BU) (lower): 5VDC is present from CB white K5 connector pin closest
to CB red K4 connector to CB K8 #5(BK) (common) at all times. If not, replace CB.
5VDC is present from CB white K5 connector pin closest to CB red K4connector
to CB K8 #6 (R) (upper) and CB K8 #7 (BU) (lower) when FS is open. If 5VDC
is present between CB K8 #5 (BK) and CB K8 #6 (R) (upper) or CB K8 #7 (BU)
(lower), FS is open. Forfurther FS diagnostics, see "II.E. Float Switch Check and
Cleaning."
5) Fill "WTRIN" LED is on: 24VAC is present at CB K2 #9 (W/R) at all times. If not,
conrm 24VAC from CB K2 #9(W/R) to a neutral (LBU). When LFS open at startup
or opens during normal operation, "WTRIN" LED turns on, ll timer (FT) starts, freeze
timer (FZT) terminates (only during normal operation), and WV energizes. If LFS is
open and "WTRIN" LED is off, conrm LFS status. See "II.E. Float Switch Check and
Cleaning." If LFS is open and "WTRIN" LED is off, replace CB. If "WTRIN" LED is on
and WV is not energized, check for 24VAC at CB K2 #8(O) to a neutral (LBU). If24VAC
is not present at CB K2 #8(O), replace CB. "WTRIN" LED turns off once UFS closes.
Ifnot, conrm UFS status. See "II.E. Float Switch Check and Cleaning." IfUFS is
closed and "WTRIN" LED is on, replace CB. If "WTRIN" LED is off and WV is open,
check for 24VAC at CB K2 #8 (O). If 24VAC is present at CB K2 #8 (O), replace CB.
If24VAC is not present, check WV diaphragm.
6) Ice Purge Cycle "GM" LED is on: When UFS closes, GM delay timer starts (5 or
30sec. depending on CB S1 dip switch #7). Once GM delay timer terminates, "GM"
LED turns on, GM and EH (-C model except FD-650) energize and 5-min. ice purge
timer starts. If GM does not energize 30 sec. after UFS closes, conrm UFS status.
See "II.E. Float Switch Check and Cleaning." If UFS is closed and GM LED does not
turn, replace CB. If "GM" LED is on and GM and EH are off, check for 115VAC from
CBK1#2to a neutral (W). If 115VAC is not present, check 115VAC power supply
connections from power switch. If 115VAC is present, check for 115VAC from CB K1
#3to a neutral (W). If115VAC is present on CB K1 #2and not on CB K1 #3, replace
CB.
28
7) Freeze Cycle "GM" and "COMP" LED are on: The 5-min. ice purge timer terminates
or the ice purge cycle bypass button ("SERVICE") is pressed, "COMP" LED turns on.
Tobypass the 5-min. Ice Purge Cycle, press the "SERVICE" button on CB after the
"GM" LED turns on. WARNING! Risk of electric shock. Care should be taken not
to touch live terminals. 115VAC is present between CB X1 relay power supply brown
(BR) or black (BK) wire and neutral (W) at all times. If not, check 115VAC power supply
wire connections from power switch. If"COMP" LED is not on after 5-min. ice purge
timer terminates, replace CB.
When "COMP" LED turns on, CR (if applicable) and compressor energize. If "COMP"
LED is on and compressor relay (CR) (if applicable) and compressor are not, check for
115VAC from CB X1 relay power supply brown (BR) or black (BK) wire to neutral (W).
If 115VAC is present, check X1 relay red (R), violet (V), or brown (BR)(FD-650 only) to
neutral (W). If 115VAC is present on X1 relay brown (BR) or black (BK) and not on X1
relay red (R), violet (V), or brown (BR)(FD-650 only), replace CB.
8) Rell "WTRIN" LED is on: See "5) Fill "WTRIN" LED is on:" above.
Legend: –bin control 1 (infrared sensor); –bin control (2) (mechanical stand-alone BC1 BC(2)
or backup); –control board; –compressor relay; –compressor CB CR CCR/GMPR
control relay/gear motor protect relay; –evaporator heater (-C model except EH
FD-650); –oat switch; –gear motor; –lower oat switch; –upper FS GM LFS UFS
oat switch; –inlet water valveWV
29
• K1 Connector
(115VAC)
GM, CCR/GMPR, EH,
FM, FMR #3
115VAC Input #2
Drain Valve
#10 (W/BU)
Control Transformer
24VAC Input
#1 (white/red)
Upper Float Switch
#6 (red) (5VDC)
Compressor Control Relay Circuit/Gear
Motor Protect Relay Circuit
#5 to #6 (white/orange)
High-Pressure Switch
#3 to #4 (yellow)
Control Switch
#1 to #2 (white/black)
• "POWER OK" LED
Control Transformer
24VAC Neutral
#2 (light blue)
Lower Float Switch
#7 (blue) (5VDC)
Float Switch-Common
#5 (black) (5VDC)
• S1 Dip Switch
• K8 Connector
(24VAC and 5VDC)
• K7 Connector-Open
• K2 Connector
(24VAC)
Fig. 3
5VDC common terminals
• K3 Connector-Open
• K4 Connector-Open
• K5 Connector-Open
Inlet Water Valve
#8 (O)
3 2 1
Control Board
Part Number 2A48054-01
(DRAIN)
• K6 Connector (20VDC)
Bin Control 1 (infrared sensor)
(dark blue)
(white, signal (common))
(brown (ground))
• J2 Connector-Open
Water Dispensing
Valve, Agitation
Motor, and Ice
Dispensing LEDs
(not used on
these models)
Control Transformer
24VAC Input
#7 (white/red)
Control Transformer
24VAC Input
#9 (white/red)
• S2 "SERVICE" Button
(Ice Purge Cycle Bypass)
Bin Control (2) (mechanical)
#3 & #4 (gray) (5VDC)
• "FLUSH" LED
(X3 Relay) (drain)
DV
• "WTRIN" LED
(X4 Relay)
WV
• "GM" LED
(X2 Relay)
GM
• "COMP" LED
(X1 Relay)
Comp, LLV, SLV
• K9 Connector (5VDC)
Control Board
30
D. Bin Control Check
1. Bin Control 1 (infrared sensor) Check
IMPORTANT
Make sure CB S1 dip switch 7 is in the "ON" position. This allows the control board
to monitor BC1 (infrared sensor) along with BC2 (mechanical) backup bin control.
1) Turn off the power supply.
2) Remove the front panel, top panel, and control box cover.
3) Conrm that CB S1 dip switch 1, 2, 3 are in the proper position for your application.
See "III.B.2. BC1 (Infrared Sensor) Shutdown Delay (S1 dip switch 1, 2, 3)."
4) Conrm that BC1 is connected to CB K6 connector. Wipe down BC1 lens with a warm,
clean, damp cloth. If the bottom of the icemaker is not accessible in your application,
remove the thumbscrew securing the BC1 housing, then remove the housing from the
base. See Fig. 4.
5) Move the control switch to the "ICE" position, then move the power switch to the "ON"
position.
6) Turn on the power supply to start the automatic icemaking process. Check that BC1
green LED is on. The BC1 green LED conrms 20VDC power from CB to BC1 and
remains on constantly. If the BC1 green LED is not on, conrm 20VDC Diagnosis:
at CB K6 #1 (DBU) to CB K6 #3 (BR). If 20VDC is present and the BC1 green LED is
off, replace BC1. If not, see step "3) BC1 (infrared sensor) Power Supply," under "II.C.
Control Board Check.
7) Make sure CB "GM" LED is on. There is a delay of at least 30 sec. before the "GM" LED
turns on after power-up. After CB "GM" LED turns on, press CB "SERVICE" button to
bypass the 5-min. ice purge cycle. WARNING! Risk of electric shock. Care should be
taken not to touch live terminals.
Fig. 4
Housing
Connector
(20VDC from
K6 connector on
control board) LEDs
Lens
Housing
Lens
LEDs
BC1 (infrared sensor)
Thumbscrew
31
8) CB "GM" and "COMP" LEDs are on. Use an object to cover BC1 lens at the bottom of
the icemaker. If the bottom of the icemaker is not accessible in your application, remove
the thumbscrew securing BC1 housing, remove the housing from the base, then cover
BC1 lens. See Fig. 4. The yellow LED on BC1 turns on (ashing or steady). The yellow
LED ashes when ice is at the outer limit of its range and turns steady as ice nears.
After the yellow LED turns on (ashing or steady), BC1 shutdown delay timer starts.
See "III.B.2. BC1 (Infrared Sensor) Shutdown Delay (S1 dip switch 1, 2, 3)." Comp
(LLV/SLV on MLH model) should de-energize immediately after the shutdown delay
timer terminates. 5 min. later, GM and FM/FMR should de-energize.
Diagnosis: If BC1 yellow LED is not on after covering the lens, replace BC1. If the
appliance remains on after BC1 shutdown delay timer terminates and the 5-min. ice
purge timer terminates, replace CB. If BC1 fails to shut down the icemaker and the level
of ice activates BC2, the icemaker shuts down and a 9-beep alarm sounds. To reset,
move the power switch to the "OFF" position, and then back to the "ON" position.
9) Remove the object covering the lens. If you removed BC1 housing from the base,
replace it in its correct position, and secure it with the thumbscrew.
10) Move the power switch to the "OFF" position. Turn off the power supply, then proceed
to "II.D.2. Bin Control 2 (mechanical stand-alone or backup) Check."
Legend: –bin control 1 (infrared sensor); –bin control 2 (mechanical stand-alone BC1 BC2
or backup); –control board; –compressor; –fan motor; –fan CB Comp FM FMR
motor-remote; –gear motor; –liquid line valve; GM LLV
SLV–suction line valve
33
6) Press the actuator paddle located in the top of the chute.
CB S1 dip switch 7 in the "ON" position: Comp (LLV and SLV on MLH model) and
GM de-energize and CB sounds a 9-beep alarm.
CB S1 dip switch 7 in the "OFF" position: Comp (LLV and SLV on MLH model) and
GM de-energize within 10 sec.
Diagnosis: If BC(2) does not open or the icemaker continues to make ice, check
that the actuator paddle is engaged. Check for continuity across BC(2) wires. If BC(2)
contacts are found open and the icemaker continues to make ice, replace CB. If BC2 is
closed with the actuator paddle engaged, replace BC(2).
7) Move the power switch to the "OFF" position and turn off the power supply.
8) Replace the chute assembly and strap in their correct positions.
9) Move the power switch to the "ON" position.
10) Replace the control box cover, top panel, and front panel in their correct positions.
11) Turn on the power supply to start the automatic icemaking process.
Legend: –bin control 1 (infrared sensor); –bin control (2) (mechanical stand-alone BC1 BC(2)
or backup); –control board; –compressor; –fan motor; –fan CB Comp FM FMR
motor-remote; –gear motor; –liquid line valve; –suction line valveGM LLV SLV
34
Red (R)
(upper oat switch)
Black (BK)
(common)
Blue (BU) (lower
oat switch)
Upper Float (blue)
Magnet (towards top)
Magnet (towards top)
Lower Float (white)
Plastic Retainer Clip
Spring Retainer Clip
Fig. 6
E. Float Switch Check and Cleaning
1. Float Switch Check
A dual oat switch is used to determine that there is sufficient water in the reservoir
during ll and rell. CB monitors UFS to de-energize WV when UFS closes during ll and
rell. CB monitors LFS to energize WV when LFS opens during the freeze cycle (rell).
CB monitors the time between LFS opening and UFS closing (90-sec. low water safety).
CB also monitors the time between UFS closing and LFS opening (30-min. freeze timer).
No adjustment is required.
1) Remove the front panel and move the power switch to the "OFF" position. Move the
control switch to the "DRAIN" position.
2) Move the power switch to the "ON" position.
3) Allow the water to drain from the reservoir, then move the power switch to the "OFF"
position and the control switch to the "ICE" position.
4) Disconnect the molex plug from the control box and check continuity across FS wires.
(BK) to (R) for UFS and (BK) to (BU) for LFS. See Fig.6. With the water reservoir
empty, FS switches are open. If open, continue to step 5. If closed, follow the steps in
"II.E.2. Float Switch Cleaning." After cleaning the oats, check them again. Replace if
necessary.
5) Reconnect the molex plug on the control box.
6) Move the power switch to the "ON" position and let the water reservoir ll.
7) Once the reservoir is full and GM starts, move the power switch to the "OFF" position.
8) Disconnect the molex plug from the control box and check continuity across FS wires.
(BK) to (R) for UFS and (BK) to (BU) for LFS. They should be closed. Clean or replace if
necessary.
36
F. Diagnostic Tables
Before consulting the diagnostic charts, check for correct installation, proper voltage per
appliance nameplate, and adequate water supply. Check control board using the steps in
"II.C. Control Board Check."
1. No Ice Production
No Ice Production - Possible Cause
Startup
1. Power Supply a) Off, blown fuse, or tripped breaker.
b) Loose connection.
c) Bad contacts.
d) Not within specications.
2. Water Supply a) Water supply off or pressure too low.
3. Power Switch
(Control Box)
a) "OFF" position.
b) Bad contacts.
4. Control Transformer a) Coil winding opened.
5. Fuse (Control Box) a) Blown.
6. BC1 (Infrared Sensor) a) No power or defective.
7. BC(2) (Mechanical
Stand-Alone or
Backup)
a) Tripped with bin lled with ice.
(9-beep alarm when used in conjunction with BC1 (infrared sensor)
b) Switch stuck open.
c) Actuator paddle does not move freely.
8. High-Pressure Switch a) Bad Contacts.
b) Dirty air lter or condenser.
c) Ambient or condenser water temperature too warm.
d) Refrigerant overcharged.
e) Fan not operating (except water-cooled model).
f) Refrigerant line or component restricted.
g) Condenser water pressure too low or off (water-cooled model).
h) Water regulating valve set too high (water-cooled model).
9. Control Switch a) "DRAIN" position. 2-beep alarm if in "DRAIN" position for more than 15 min.
b) Bad contacts.
Fill Cycle
1. Control Board a) No Power to inlet water valve.
b) No power to oat switch or not reading oat switch condition.
2. Inlet Water Valve a) Screen or orice clogged.
b) Coil winding opened.
3. Float Switch a) Float does not move freely.
b) Defective.
4. Drain Water Valve a) Valve seat clogged and water leaking.
5. Hoses a) Disconnected.
37
Ice Purge Cycle
1. Control Board a) No power to gear motor.
b) No power to compressor control relay.
2. Gear Motor a) Blown fuse.
b) Internal protector open.
c) Defective.
Freeze Cycle
1. Compressor Control
Relay
a) No voltage from gear motor.
b) Defective.
2. Control Board a) Defective.
3. Start Relay a) Bad contacts.
b) Coil winding opened.
c) Loose connections.
4. Capacitor (start or run) a) Defective, weak.
5. Power Supply a) Not within specications.
6. Refrigerant Line a) Gas leaks.
b) Refrigerant line or component restricted.
7. Thermostatic
Expansion Valve
(TXV) (not adjustable)
a) Defective.
8. Compressor a) Defective.
9. Liquid Line Valve
(MLH models)
a) Defective.
10. Suction Line Valve
(MLH models)
a) Defective.
11. Fan Motor
(if applicable)
a) Compressor Control Relay/Magnetic Contactor defective.
b) Defective capacitor.
c) Defective.
d) Control board defective.
12. Evaporator a) Dirty.
b) Damaged or defective.
13. Headmaster (C.P.R.)
(remote air-cooled
model)
a) Not operating properly and liquid line temperature too warm.
14. Water Supply Line
(water-cooled model)
a) Condenser water pressure too low or off and high pressure control opens and
closes frequently.
15. Water Regulating
Valve
(water-cooled model)
a) Set too high.
16. Magnetic Contactor
(if applicable)
a) Defective.
17. Drain Valve a) Dirty, leaking by.
b) Defective.
18. Water System a) Water leaks.
38
Rell
1. Float Switch a) Dirty/sticking.
b) Defective.
2. Inlet Water Valve a) Clogged or defective.
3. Water Supply a) Off.
4. Control Board a) No power to oat switch or not reading oat switch condition.
b) No power to inlet water valve.
Shutdown
1. BC1 (Infrared Sensor)
See "II.D. Bin Control
Check."
a) Dirty lens.
b) Defective.
2. BC(2) (Mechanical
Stand-Alone or
Backup)
See "II.D. Bin Control
Check."
a) Actuator paddle does not move freely.
b) Defective.
3. Control Board a) Control board dip switches set incorrectly.
b) In alarm.
c) Defective.
Drain Cycle
1. Drain Valve a) Screen or orice clogged.
b) Defective.
2. Control Board a) Defective.
39
III. Controls and Adjustments
A. Control Board
• A Hoshizaki exclusive control board is employed.
• All models are pretested and factory adjusted.
• For a control board check procedure, see "II.C. Control Board Check."
NOTICE
• Fragile, handle very carefully.
• The control board contains integrated circuits, which are susceptible to failure
due to static discharge. It is especially important to touch the metal part of the
icemaker when handling or replacing the control board.
• Do not touch the electronic devices on the control board or the back of the control
board.
• Do not change wiring and connections. Do not misconnect terminals.
• Do not short out power supply to test for voltage.
• Always replace the whole control board assembly if it goes bad.
40
1. Control Board Layout
• K1 Connector
(115VAC)
GM, CCR/GMPR, EH,
FM, FMR #3
115VAC Input #2
Drain Valve #10
Control Transformer
24VAC Input
#1 (white/red)
Upper Float Switch
#6 (red) (5VDC)
Compressor Control Relay Circuit/Gear
Motor Protect Relay Circuit
#5 to #6 (white/orange) (5VDC)
High-Pressure Switch
#3 to #4 (yellow) (5VDC)
Control Switch
#1 to #2 (white/black) (5VDC)
• "POWER OK" LED
Control Transformer
24VAC Neutral
#2 (light blue)
Lower Float Switch
#7 (blue) (5VDC)
Float Switch
#5 (black) (5VDC)
• S1 Dip Switch
• K8 Connector
(24VAC and 5VDC)
• K7 Connector-Open
• K2 Connector
(24VAC)
5VDC common terminals
• K3 Connector-Open
• K4 Connector-Open
• K5 Connector-Open
Inlet Water
Valve #8
3 2 1
(DRAIN)
• K6 Connector (20VDC)
Bin Control 1 (infrared sensor)
(dark blue)
(white, signal (common))
(brown (ground))
• J2 Connector-Open
Water Dispensing
Valve, Agitation
Motor, and Ice
Dispensing LEDs
(not used on
these models)
Control Transformer
24VAC Input
#7 (white/red)
Control Transformer
24VAC Input
#9 (white/red)
• S2 "SERVICE" Button
(Ice Purge Cycle Bypass)
Bin Control (2) (mechanical)
#3 & #4 (gray) (5VDC)
• "FLUSH" LED
(X3 Relay) (drain)
DV
• "WTRIN" LED
(X4 Relay)
WV
• "GM" LED
(X2 Relay)
GM
• "COMP" LED
(X1 Relay)
Comp, LLV, SLV
• K9 Connector (5VDC)
Control Board
Part Number 2A8054-01
42
3. Ice Purge Cycle Bypass
To speed up the diagnostic process, the 5-min. ice purge cycle may be bypassed
by pressing the "SERVICE" button on the control board after the gear motor starts.
WARNING! Risk of electric shock. Care should be taken not to touch live terminals.
B. Controls and Adjustments
NOTICE
Dip switches are factory set. Failure to maintain factory settings may adversely
affect performance and warranty coverage. For more information, contact your
Hoshizaki Certied Service Representative.
1. Default Dip Switch Settings
The S1 dip switch settings are factory-set to the following positions:
a) Single Bin Control Models (BC Mech. Stand-Alone or BC2 Backup Only)
Dip Switch No. 1 2 3 4 5 6 7 8 9 10
F-1001M_H(-C) OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
F-1001M_J(-C) OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
b) Multiple Bin Control Models (BC1 Infrared Sensor and BC2 Backup)
Dip Switch No. 1 2 3 4 5 6 7 8 9 10
F-1501M_H(-C) ON OFF OFF OFF OFF OFF ON ON OFF OFF
F-2001M_H(3)(-C) ON OFF OFF OFF OFF OFF ON ON OFF OFF
FD-1001M_H-C ON OFF OFF OFF OFF OFF ON ON OFF OFF
FD-1001M_J-C ON OFF OFF OFF OFF OFF ON ON OFF OFF
c) Single Bin Control Models (BC1 Infrared Sensor Only)
Dip Switch No. 1 2 3 4 5 6 7 8 9 10
F-450MAJ(-C) ON OFF OFF OFF OFF OFF ON ON OFF OFF
F-801M_J(-C) ON OFF OFF OFF OFF OFF ON ON OFF OFF
F-1002M_J(-C) ON OFF OFF OFF OFF OFF ON ON OFF OFF
F-1501M_J(-C) ON OFF OFF OFF OFF OFF ON ON OFF OFF
F-2001M_J(-C) ON OFF OFF OFF OFF OFF ON ON OFF OFF
FD-650M_H-C ON OFF OFF OFF OFF OFF ON ON OFF OFF
FD-1002M_J-C ON OFF OFF OFF OFF OFF ON ON OFF OFF
Bin Control 1 (infrared sensor) Shutdown Delay
Continuous Dispensing Timer
(DCM models only, do not adjust on modular icemakers)
Drain Frequency Control
Bin Control Selector
Bin Control (BC or BC2) (mechanical stand-alone or backup) Shutdown Delay
Normally off (factory use)
45
C. Power Switch and Control Switch
The power switch and the control switch are used to control the icemaker. They are
located on the control box.
1. Power Switch
The power switch has 2 positions, "OFF" and "ON." When the power switch is in the
"OFF" position, no power is supplied to the components. When in the "ON" position,
power is supplied to the control transformer and control board. The control board then
supplies 5VDC to the control switch for unit operation.
2. Control Switch
The control switch has 2 positions, "ICE" and "DRAIN."
When the control switch is in the "ICE" position (open), icemaking begins.
When the control switch is in the "DRAIN" position (closed), the drain valve energizes.
a) ICE
When the control switch is in the "ICE" position, the control board reads an open
circuit through the control switch contacts and starts the icemaking process.
b) DRAIN
When the control switch is in the "DRAIN" position, the control board reads a closed
circuit through the control switch and the drain valve energizes.IV. Refrigeration Circuit
and Component Service Information
48
6) A liquid charge is required when charging an R-404A system (to prevent fractionation).
Place the service cylinder on the scales; if the service cylinder is not equipped with
a dip tube, invert the service cylinder, then place it on the scales. Open the high-side
valve on the gauge manifold.
7) Allow the system to charge with liquid until the proper charge weight is met.
8) If necessary, add any remaining charge to the system through the low-side.
NOTICE!To prevent compressor damage, use a throttling valve or liquid
dispensing device to add the remaining liquid charge through the low-side
refrigerant access valve with the icemaker running.
9) Close the high and low-side gauge manifold valves, then disconnect the gauge manifold
hoses.
10) Cap the refrigerant access valves to prevent a possible leak.

Produkt Specifikationer

Mærke: Hoshizaki
Kategori: Ismaskine
Model: FD-1002MAJ-C

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