Hoshizaki Hoshizaki America, Inc. Self-Contained Cubelet Models C-100BAF-AD C-100BAF-ADDS “A Superior Degree of Reliability” SERVICE MANUAL www.hoshizaki.
IMPORTANT Only qualified service technicians should install, service, and maintain the icemaker. No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the equipment in accordance with this manual may adversely affect safety, performance, component life, and warranty coverage. Hoshizaki provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker.
Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, or damage to the unit. WARNING Indicates a hazardous situation which could result in death or serious injury. CAUTION Indicates a situation which could result in damage to the unit. IMPORTANT Indicates important information about the use and care of the unit.
IMPORTANT This manual should be read carefully before the icemaker is serviced or maintenance operations are performed. Only qualified service technicians should install, service, and maintain the icemaker. Read the warnings contained in this booklet carefully as they give important information regarding safety. Please retain this booklet for any further reference that may be necessary. CONTENTS Important Safety Information....................................................................................
C. Removal and Replacement of Evaporator Assembly Components.............................. 30 1. Upper Bearing Wear Check ................................................................................... 31 2. Removal and Replacement of Extruding Head....................................................... 32 3. Removal and Replacement of Auger...................................................................... 32 4. Removal and Replacement of Evaporator...................................................
I. Specifications A. C-100BAF-AD, C-100BAF-ADDS AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.
II. General Information A. Construction 1. Icemaker Ice Discharge Opening Bin Control Thermostat Bulb Slope Front Panel Air-Cooled Condenser and Condenser Fan Motor Power Switch Control Box Louver Gear Motor Protector (External Overload) Reset Switch Front C-100BAF-AD Shown Bin Control Thermostat Top Panel Float-Operated Water Valve Water Reservoir Suction Temperature Safety Evaporator Assembly Upper Rear Panel Gear Motor Compressor Lower Rear Panel Drier Rear C-100BAF-AD Shown 7 Fig.
2. Ice Making Unit Cutter (motionless) Allen Head Cap Screw Evaporator Flange Extruding Head and Upper Bearing Auger Cylinder Insulation Gear Motor Mechanical Seal O-Ring Housing and Lower Bearing Allen Head Cap Screw with Washer Spline Coupling Hex Head Bolt with Washer Fig.
B. Sequence of Operation This icemaker utilizes a thermostatic bin control to switch the gear motor, fan motor, and compressor on and off as needed. This icemaker utilizes a float-operated water valve in the water reservoir to allow water into the icemaker as needed. After the power switch is placed in the "ON" position, the sequence is as follows: 1. Freeze Cycle GM, FM, CR, and Comp energize. As the water in the evaporator cools, ice starts forming within 4 to 6 minutes.
III. Technical Information A. Water Circuit and Refrigeration Circuit 1. C-100BAF Series Float-Operated Water Valve Water Inlet Water Reservoir Water Level Evaporator Assembly Water Supply Gear Motor Overflow Hose Capillary Tube Drier Condenser Condenser Fan Motor Suction Temperature Safety Discharge Suction Compressor Fig.
B. Wiring Diagram 1. C-100BAF Series (external overload 2.4~3.0A) (3W) (internal) (external) 2. C-100BAF Series with Optional Drain Pump HS-0248 (external overload 2.4~3.
3. Sequence Wiring Diagram a) Freeze Cycle Power supplied. Gear motor, fan motor, compressor relay, and compressor energize. The float-operated water valve allows water into the reservoir as needed to continue the ice making process. (external overload 2.4~3.
b) Bin Control Thermostat Shutdown Ice fills storage bin to level of bin control thermostat. Bin control thermostat opens. Gear motor, fan motor, compressor relay, and compressor de‑energize. (external overload 2.4~3.
c) Low Water/Freeze-Up Safety Shutdown If the water supply is interrupted or a freeze-up condition occurs, the decrease in suction line temperature causes the suction temperature safety to open and shut down the icemaker. See the table below for suction temperature safety cut-out/cut-in temperatures. Suction Temperature Safety Cut-out 23.9°F±2.7°F (-4.5°C±1.5°C) Cut-in 29.0°F±2.7°F (-1.5°C±1.5°C) (external overload 2.4~3.
d) Gear Motor Protector (external overload) Shutdown If gear motor amperage exceeds 2.4~3.0 amps, the gear motor protector (external overload) operates independently to turn off the gear motor. The gear motor external overload can be manually reset by pressing the switch on the control box. (external overload 2.4~3.
e) Optional Drain Pump HS-0248 Safety Shutdown If the water level in the drain pump reservoir rises high enough to close the drain pump upper float switch, the drain pump safety interrupts power to the icemaker. When the water level lowers enough to open the drain pump upper float switch, power is restored to the icemaker. The pump motor remains energized as long as the drain pump lower float switch is closed. (external overload 2.4~3.
C. Performance Data 1. C-100BAF-AD, C-100BAF-ADDS APPROXIMATE ICE PRODUCTION PER 24 HR. AMBIENT TEMP. (ºF/ºC) 70/21 80/27 90/32 lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION 100/38 WATER TEMP. (ºF/ºC) 50/10 92 81 66 55 70/21 80/27 90/32 watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 100/38 70/21 80/27 90/32 3 gal.
IV. Service Diagnosis WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Risk of electric shock. Use extreme caution and exercise safe electrical practices. 3. Moving parts (e.g., fan blade) can crush and cut. Keep hands clear. 4. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the unit is serviced. Make sure that none have fallen into the storage bin.
5) Shutdown (bin full) – Ice fills storage bin to level of BC. BC opens. GM, FM, CR, and Comp de‑energize. Diagnosis: When the icemaker is running, hold ice in contact with BC bulb. If the components fail to de‑energize, check BC. 6) Move the power switch to the "OFF" position and unplug the unit from the electrical outlet. 7) Make any repairs necessary, then replace the removed parts in the reverse order of which they were removed. 8) Plug the unit back in.
C. Diagnostic Charts 1. No Ice Production Problem Possible Cause [1] The icemaker will not a) Power Supply start. Remedy 1. Off, blown fuse, or tripped breaker. 1. Turn on, replace, or reset. 2. Power cord unplugged. 2. Plug into outlet. 3. Loose connection. 3. Tighten. 4. Bad contacts. 4. Check for continuity and replace. 5. Not within specifications. 5. Refer to nameplate and correct. b) Power Switch (Control Box) 1. "OFF" position. 1. Move to "ON" position. 2. Bad contacts. 2.
Problem Possible Cause [1] The icemaker will not f) Gear Motor Internal start (continued). Overload (Thermal Protector) [2] Gear motor starts, but compressor will not start or operates intermittently. Remedy 1. Open. 1. Allow to cool and reset. Check gear motor bearings, auger bearings (see "V.C.1. Upper Bearing Wear Check"), and supply voltage. Check for evaporator freeze-up. g) Optional Drain Pump HS-0248 Safety 1. Open. 1. Check drain pump. See "IV.D. Optional Drain Pump HS-0248.
Problem Possible Cause [4] Gear motor and b) Refrigerant Line compressor start, but no ice is produced (continued). Remedy 1. Gas leaks. 1. Check for leaks with a leak detector. Recover, repair, replace drier, evacuate, and recharge. See "V.A. Service for Refrigerant Lines." 2. Refrigerant lines or 2. Recover, repair, replace components restricted. drier, evacuate, and recharge. See "V.A. Service for Refrigerant Lines." c) Gear Motor 1. Spline coupling or 1.
3. Other Problem [1] Abnormal noise. Possible Cause a)Fan Motor b)Compressor Remedy 1. Bearing worn out. 1. Replace fan motor. 2. Fan blade deformed. 2. Replace fan blade. 3. Fan blade does not move freely. 3. Replace fan blade and/or fan motor. 1. Mounting pad out of position. 1. Reinstall. 2. Bearings worn out or 2. Replace compressor. cylinder valve broken. c) Refrigerant Lines 1. Rub or touch lines or other surfaces. 1. Reposition. d)Auger 1. Bearings or auger worn out. 1.
D. Optional Drain Pump HS-0248 1. Overview As ice melts, water drains from the storage bin into the drain pump reservoir. When the drain pump's lower float switch closes, the pump motor energizes and pumps out the water. If water cannot be pumped out of the drain pump reservoir due to a blocked discharge hose, bad check valve, or bad pump motor, the upper float switch closes as the water level in the pump rises. When the upper float switch closes, this activates the safety.
7) Make sure all hose connections are secure, then reinstall the lower rear panel and upper rear panel in their correct positions. WARNING! Make sure that there are no wires pinched between the rear covers and icemaker. 8) Resecure the vent hose to the icemaker. CAUTION! The vent hose must be attached and secured to the icemaker or water damage may occur. Make certain there are no kinks in the vent hose. The drain pump will not operate correctly with a partially blocked vent hose.
V. Removal and Replacement of Components WARNING 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Move the power switch to the "OFF" position and unplug the unit from the electrical outlet before servicing. 3. CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the unit is serviced. Make sure that none have fallen into the storage bin. 4.
2. Brazing WARNING 1. R-134a itself is not flammable at atmospheric pressure and temperatures up to 212°F (100°C). 2. R-134a itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R-134a can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous. 3. Do not use silver alloy or copper alloy containing arsenic. 4. Use an electronic leak detector or soap bubbles to check for leaks.
6) A liquid charge is recommended when charging an R-134a system. 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) Close the high-side valve on the gauge manifold, then close the refrigerant access valve (if applicable). Disconnect the gauge manifold hose.
15) Evacuate the system, then charge it with refrigerant. See the nameplate for the required refrigerant charge. 16) Connect the terminals and replace the terminal cover in its correct position. 17) Replace the control box, louver, and panels in their correct positions. 18) Plug the unit back in. Move the power switch to the "ON" position.
C. Removal and Replacement of Evaporator Assembly Components Thumbscrew Spout Cutter (motionless) Packing Evaporator Flange Allen Head Cap Screw Extruding Head and Upper Bearing Evaporator Drain Hose Connection Auger Reservoir Hose Connection Spring Retainer Allen Head Cap Screw with Washer Mechanical Seal O-Ring Hex Head Bolt with Washer Housing and Lower Bearing Spline Coupling Fig.
1. Upper Bearing Wear Check To ensure that the bearing inside the extruding head does not exceed the wear tolerance of .02", follow the instructions below. 1) Move the power switch to the "OFF" position, then unplug the unit from the electrical outlet. 2) Remove all ice from the storage bin. 3) While maintaining a hold on the door, remove the hinge stop pin from hinge (B). Pull out the bottom of the door slightly, then gently remove the door from hinge (A). See Fig. 7. 4) Remove the top panel.
2. Removal and Replacement of Extruding Head 1) Move the power switch to the "OFF" position, then unplug the unit from the electrical outlet. 2) Close the water supply line shut-off valve. 3) Remove all ice from the storage bin. 4) While maintaining a hold on the door, remove the hinge stop pin from hinge (B). Pull out the bottom of the door slightly, then gently remove the door from hinge (A). See Fig. 7. 5) Remove the top panel. Spout Packing 6) Remove the spout. 7) Remove the upper rear panel. See Fig.
8) Remove the clamp securing the drain plug, then lower the drain hose into a container. Remove the drain plug to drain the water from the reservoir and evaporator assembly. 9) After all of the water has drained, replace the drain hose, drain plug, and drain clamp in their original positions. 10) Remove the packing. 11) Remove the allen head cap screws securing the extruding head and evaporator flange. Remove the evaporator flange, then grasp the cutter and carefully lift out the cutter and extruding head.
9) Disconnect the drain hose and reservoir hose from the evaporator. 10) Remove the packing. 11) Remove the allen head cap screws securing the extruding head and evaporator flange. Remove the evaporator flange, then grasp the cutter and carefully lift out the cutter and extruding head. Grasp the top of the auger and carefully lift out the auger. When pulling out the auger, the upper part of the mechanical seal should come out with it. 12) Remove the evaporator condensate drain pan.
5. Removal and Replacement of Mechanical Seal and Lower Housing 5a. Mechanical Seal 1) Move the power switch to the "OFF" position, then unplug the unit from the electrical outlet. 2) Close the water supply line shut-off valve. 3) Remove all ice from the storage bin. 4) While maintaining a hold on the door, remove the hinge stop pin from hinge (B). Pull out the bottom of the door slightly, then gently remove the door from hinge (A). See Fig. 7. 5) Remove the top panel. 6) Remove the spout.
18) Install the lower part of the mechanical seal onto the lower housing. 19) Lower the evaporator down and secure it to the lower housing. 20) Install the auger assembly with the upper part of the mechanical seal attached. Replace the cutter, extruding head, and evaporator flange in their correct positions. 21) Open the water supply line shut-off valve and check for water leaks. Replace the removed parts in the reverse order of which they were removed. 22) Plug the unit back in.
the fan motor assembly into the unit. Connect the fan motor wires, then replace the removed parts in the reverse order of which they were removed. 6) Replace the louver and panels in their correct positions. 7) Plug the unit back in. Move the power switch to the "ON" position. E. Removal and Replacement of Water Reservoir 1) Move the power switch to the "OFF" position, then unplug the unit from the electrical outlet. 2) Close the water supply line shut-off valve. 3) Remove the upper rear panel. See Fig. 9.
VI. Cleaning and Maintenance This icemaker must be cleaned and maintained in accordance with the instruction manual and labels provided with the icemaker. Consult with your local distributor about cleaning and maintenance service. To obtain the name and phone number of your local distributor, visit www.hoshizaki.com or call Hoshizaki Technical Support at 1‑800‑233‑1940 in the USA. WARNING 1. Only qualified service technicians should attempt to service this icemaker. 2.
3) While maintaining a hold on the door, remove the hinge stop pin from hinge (B). Pull out the bottom of the door slightly, then gently remove the door from hinge (A). See Fig. 10. 4) Remove the 2 screws securing the top panel, then lift it off. 5) Remove all ice from the storage bin. 6) Remove the slope from the storage bin by carefully bending it in the center and releasing it from the 2 slope shafts. 7) Remove the scoop. Remove the 2 thumbscrews securing the scoop holder, then remove it.
12) Allow the icemaker to sit for 10 minutes before operation. If you placed a clamp on the reservoir hose in step 11, remove it before operation and replace the spout in its correct position. 13) Plug the unit back in. Move the power switch to the "ON" position. 14) Allow the unit to make ice using the solution. When ice stops coming out, move the power switch to the "OFF" position. Unplug the unit from the electrical outlet. 15) Remove the drain plug to drain any remaining solution.
5. Sanitizing Procedure - Final 1) Remove the drain plug to drain any remaining solution. 2) After all of the solution has drained, replace the drain plug in its correct position. 3) Remove the reservoir cover. Pour the sanitizing solution into the reservoir until the solution starts to flow through the overflow hose. 4) Allow the icemaker to sit for 10 minutes before operation. 5) Plug the unit back in. Move the power switch to the "ON" position. 6) Allow the unit to make ice using the solution.
B. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the icemaker's environment, and local sanitation regulations. WARNING 1. Only qualified service technicians should attempt to service this icemaker. 2. Move the power switch to the "OFF" position and unplug the unit from the electrical outlet before servicing. Maintenance Schedule Frequency Area Task Weekly Monthly Clean the scoop using a neutral cleaner.
1. Storage Bin Drain In some conditions, slime may build up inside the storage bin drain and prevent water from draining properly. To prevent this buildup, perform the following procedure once every 3 months or as often as necessary for conditions. 1) Move the power switch to the "OFF" position. 2) Remove all ice from the storage bin. 3) Mix a batch of sanitizing solution by diluting 1.25 fl. oz. (37 ml or 2.5 tbs) of a 5.25% sodium hypochlorite solution (chlorine bleach) with 2.5 gallons (9.
C. Preparing the Icemaker for Long Storage CAUTION When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. When the icemaker is not used for two or three days under normal conditions, it is sufficient to move the power switch to the "OFF" position. When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below.
