Service Manual Self-Contained Flaker Models F-300BAJ F-500BAJ hoshizakiamerica.
WARNING Only qualified service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certified 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.
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. CONTENTS Important Safety Information.................................................................................................. 4 I.
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 use and care of the appliance.
WARNING, continued For Corded Models • This appliance is equipped with a NEMA 5-15 three‑prong grounding plug to reduce the risk of potential shock hazards. Corded models must be plugged into a properly grounded, independent 3-prong wall outlet. If the outlet is a 2-prong outlet, it is your personal responsibility to have a qualified electrician replace it with a properly grounded, independent 3-prong wall outlet. Do not remove the ground prong from the plug and do not use an adapter plug.
WARNING, continued • Do not use combustible spray or place volatile or flammable substances near the appliance. They might catch fire. • Keep the area around the appliance clean. Dirt, dust, or insects in the appliance could cause harm to individuals or damage to the appliance. • Do not place anything on top of the appliance. Foreign objects or moisture could enter the appliance and result in electric shock or fire. NOTICE • Protect the floor when moving the appliance to prevent damage to the floor.
I. Construction and Water/Refrigeration Circuit Diagram A. Construction 1. F-300BAJ Bin Control The actuator is located in the ice storage bin.
2. F-500BAJ Bin Control The actuator is located in the ice storage bin.
B. Icemaking Unit 1.
C.
5 min. 30-min. FZT 11 Legend: BC-bin control CB-control board Comp-compressor DC-drain cycle DT-drain timer DV-drain valve FM-fan motor 1. DT Initiates DC DV energizes for 2 sec. 1. DT Initiates DC Continued uninterrupted operation FT-fill timer (low water safety) FZT-freeze timer GM-gear motor LFS-lower float switch PT-purge timer UFS-upper float switch WV-inlet water valve (CB S1 dip switch 4 "ON") 3. 1-in-12 Drain Cycle & Restart (optional) (CB S1 dip switch 4 "OFF") 2.
BC open (BC actuator paddle engaged) 60 sec. 3. Icemaker Off Legend: BC-bin control Comp-compressor DC-drain cycle DT-drain timer DV-drain valve FM-fan motor FT-fill timer (low water safety) GM-gear motor LFS-lower float switch PT-purge timer UFS-upper float switch WV-inlet water valve to "2. Ice Purge Cycle" above if UFS closed. to "1. Fill Cycle" above if UFS open. 4.
B. Service Diagnosis WARNING • The appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Risk of electric shock. Use extreme caution and exercise safe electrical practices. • Moving parts (e.g., fan blade or auger) can crush and cut. Keep hands clear. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the appliance is serviced.
2. Diagnostic Procedure This diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components. Before proceeding, check for correct installation, proper voltage per appliance nameplate, and adequate water pressure (10 PSIG to 113 PSIG). Note: • When checking high voltage (115VAC), always choose a neutral (W) wire to establish a good neutral connection. • When checking low voltage (24VAC), always choose a neutral (LBU) wire to establish a good neutral connection.
6) Startup–CB "POWER OK" LED is on. Plug the appliance into the electrical outlet (F-300BAJ) or turn on the power supply (F-500BAJ), then move the power switch to the "ON" position. Make sure the control switch is in the "ICE" position. CB "POWER OK" LED turns on. Diagnosis CB "POWER OK" LED: Check that CB "POWER OK" LED is on. If not, check for 115VAC at control transformer black (BK) wire to neutral (W). If 115VAC is not present, check the power switch, power supply cord, and breaker.
8) Ice Purge Cycle – "GM" LED is on. 5-sec. GM delay timer terminates. GM and CCR energize. Once CCR energizes, 5VDC circuit closes through CCR terminal #3 (W/O) and terminal #5 (W/O) and CB K9 #5 (W/O) and K9 #6 (W/O). After 5VDC circuit closes, 5-min. ice purge timer starts. 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.
10) Refill Cycle – "GM", "COMP", and "WTRIN" LEDs are on. LFS opens. WV energizes and 90-sec. FT starts. Comp, GM, CCR, and FM continue. LFS closes. Nothing occurs at this time. Reservoir continues to fill until UFS closes. When UFS closes, WV de-energizes, 90-sec. FT terminates, and 30-min. FZT starts. If UFS remains open longer than 90 sec. after LFS opens, FT exceeded and CB sounds a 1-beep alarm. WV remains energized until UFS closes. Alarm resets automatically when UFS closes.
11) Drain Cycle a) 1-in-1 Drain Cycle: DV energizes once every hour when the 1-in-1 drain cycle is activated (S1 dip switch 4 in the "OFF" position (factory default position)). GM, FM, Comp continue. DV energizes for 2 sec. every hour. This setting is recommended for optimum icemaker performance. The 1‑in-1 drain cycle allows any sediment to drain from the evaporator without interrupting the icemaking process.
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: S1 dip switch 7 in the "OFF" position.
a) Control Switch – CB K9 #1 (W/BK) and CB K9 #2 (W/BK): 5VDC is present between CB white K5 connector, pin closest to CB red K4 connector and CB K9 #1 (W/BK) at all times. If 5VDC is not present, replace CB. When the control switch is in the "ICE" position, the control switch contacts are open. 0VDC is present between CB white K5 connector, pin closest to CB red K4 connector and CB K9 #2 (W/BK). When in the "ICE" position, 5VDC is present between CB K9 #1 (W/BK) to CB K9 #2 (W/BK).
5) Fill "WTRIN" LED is on: 24VAC is present at CB K2 #9 (W/R) at all times. If not, confirm 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, fill timer (FT) starts, freeze timer (FZT) terminates (only during normal operation), and WV energizes. If LFS is open and "WTRIN" LED is off, confirm LFS status. See "II.E. Float Switch Check and Cleaning." If LFS is open and "WTRIN" LED is off, replace CB.
"F-C" Control Board • K9 Connector (5VDC) Control Switch #1 to #2 (white/black) (5VDC) • "GM" LED (X2 Relay) GM High-Pressure Switch #3 to #4 (yellow) (5VDC) Compressor Control Relay Circuit/Gear Motor Protect Relay Circuit #5 to #6 (white/orange) (5VDC) • "COMP" LED (X1 Relay) Comp • S2 "SERVICE" Button (Ice Purge Cycle Bypass) • K8 Connector • K1 Connector (115VAC) GM, CCR, EH (-C model), FM, #3 115VAC Input #2 • K2 Connector Control Transformer 24VAC Input #1 (white/red) Control Transformer 24VAC
D. Bin Control Check Bin Control Check When the actuator paddle is not engaged BC is closed and the icemaker produces ice. With CB S1 dip switch 7 placed in the "OFF" position, BC is used as a stand-alone bin control. The stand-alone application should only be used in standard ice storage bin applications. When ice fills the chute and engages the actuator paddle, BC opens and CB starts the 150-sec. shutdown sequence.
6) Reconnect the 12 pin connector to the control box or re-connect wires with new bell connectors. 7) Remove the control box cover, then plug the appliance into the electrical outlet (F-300BAJ) or turn on the power supply (F-500BAJ). Next, confirm the control switch is in the "ICE" position, then move the power switch to the "ON" position. 8) Wait for the "GM" LED to turn on. There is a delay of at least 5 seconds before the "GM" LED turns on after power‑up.
E. Float Switch Check and Cleaning 1. Float Switch Check A dual float switch is used to determine that there is sufficient water in the reservoir during fill and refill. CB monitors UFS to de-energize WV when UFS closes during fill and refill. CB monitors LFS to energize WV when LFS opens during the freeze cycle (refill). 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).
2. Float Switch Cleaning Depending on local water conditions, scale may build up on FS. Scale on FS can cause the floats to stick. In this case, FS should be cleaned and checked. 1) If not already removed, remove the front panel. 2) Move the power switch to the "OFF" position, then unplug the appliance from the electrical outlet (F-300BAJ) or turn off the power supply (F-500BAJ). 3) Remove the float switch assembly from the reservoir cover. See Fig. 4.
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) Unplugged, off, blown fuse, or tripped breaker. b) Not within specifications. 2. Water Supply a) Water supply off or improper water pressure (10 to 113 PSIG). b) External water filters clogged. 3.
No Ice Production - Possible Cause Freeze Cycle 1. Control Board a) Defective. See "II.C. Control Board Check." 2. Start Relay/Capacitor a) Defective. 3. Compressor a) Open motor windings. b) Mechanical Failure. 4. Fan Motor a) Open motor windings. b) Mechanical failure or fan blade binding. 5. Evaporator a) Dirty. b) Damaged or defective. 6. Refrigerant Charge a) Low. 7. Drain Valve a) Dirty, leaking by. 8. Water System a) Water leaks. 9. Evaporator Heater (-C model) a) Defective. Refill 1.
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.
1.
2. LED Lights and Audible Alarm Safeties The "POWER OK" LED indicates proper control voltage and will remain on unless a control voltage problem occurs. For further details, see "II.A. Sequence of Operation Flow Chart." Energized Components Sequence Step LED Fill Cycle Ice Purge Cycle Freeze Cycle (with refill) WTRIN GM GM, WTRIN* (refill), COMP WV GM GM, Comp, FM, WV* (refill) 1-in-1 hr or 1-in-12 hr Drain Cycle FLUSH (Drain) 1-in-1: DV-Icemaker 2 sec.
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 Certified Service Representative. 1. Default Dip Switch Settings The S1 dip switch settings are factory-set to the following positions: Dip Switch No.
2. Infrared Sensor Shutdown Delay (S1 dip switch 1, 2, 3). Infrared sensor shutdown delay is the delay between the infrared sensor detecting ice (infrared sensor yellow LED flashing or steady) and the start of the shutdown sequence. For dispenser unit applications, the ice level at shutoff may need to be adjusted depending on the dispenser agitation or dispense method. Increasing the shutdown delay setting allows for a higher level of ice in the bin before the icemaker shuts down.
5. Bin Control Selector (S1 dip switch 7) The bin control selector is factory set. Do not adjust. When used on a standard ice storage bin, only the mechanical bin control should be used. When the mechanical bin control is used (S1 dip switch 7 in the off position), the gear motor delay after the upper float switch closes is 5 sec. WARNING! Do not adjust S1 dip switch 7 out of the factory default position. This dip switch must be left in the factory default position.
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.
IV. Refrigeration Circuit and Component Service Information WARNING • This appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Move the power switch to the "OFF" position and turn off the power supply. Place the disconnect in the "OFF" position. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.
2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). • R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R-404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous. • Do not use silver alloy or copper alloy containing arsenic. 1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
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.
B. Component Service Information NOTICE • When replacing a component listed below, see the notes to help ensure proper operation. • When replacing evaporator assembly and water circuit components, make sure there are no water leaks after the repair is complete. • Seal bolts must be replaced once removed because seal material is one-time use only. If new seal bolts do not have preapplied threadlocker, apply Loctite 243 or equivalent threadlocker to seal bolt threads. Tighten to the torque value listed below.
Evaporator Assembly Flaker Cutter Upper Bearing (pressed into extruding head) Flaker Extruding Head Auger O Ring Evaporator Flange Packing Seal Bolts Inspect for leakage around seal bolts. Tighten (11.1 ft-lb/15 N·m) or replace as necessary. Seal bolts must be replaced once removed because seal material is one-time use only. Loctite 243 must be applied to seal bolt threads when seal bolts are replaced.
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) Remove the front panel. Move the power switch to the "OFF" position, then unplug the appliance (F-300BAJ) or turn off the power supply (F-500BAJ). 2) Remove the top and side panels. 3) Remove the strap connecting the spout to the chute assembly, then remove the spout.
6) Replace the spout. 7) Replace the top and side panels in their correct position. 8) Move the power switch to the "ON" position. 9) Replace the front panel in its correct position, then plug the appliance into the electrical outlet (F-300BAJ) or turn on the power supply (F-500BAJ). IMPORTANT! Seal Bolt Removal and Installation Instructions: Seal bolts must be replaced once removed because seal material is one-time use only.
4. Removal and Replacement of Auger 1) Drain the water from the evaporator. a) Remove the front panel, then move the power switch to the "OFF" position. b) Move the control switch to the "DRAIN" position. c) Move the power switch to the "ON" position and allow the water to drain from the evaporator. d) Move the power switch to the "OFF" position, then unplug the appliance (F-300BAJ) or turn off the power supply (F-500BAJ). 2) Remove the top and side panels.
8) Disconnect the inlet and outlet tubing. 9) Remove the socket head cap screws and split lock washers securing the evaporator to the lower housing. 10) Lift off the evaporator. 11) Inspect the mechanical seal and O-ring prior to installing the new evaporator. The mechanical seal consists of two parts. One moves along with the auger, and the other is fixed on the lower housing.
6. Removal and Replacement of Mechanical Seal and Lower Housing 6a. Mechanical Seal 1) Drain the water from the evaporator. a) Remove the front panel, then move the power switch to the "OFF" position. b) Move the control switch to the "DRAIN" position. c) Move the power switch to the "ON" position and allow the water to drain from the evaporator. d) Move the power switch to the "OFF" position, then unplug the appliance from the electrical outlet (F-300BAJ) or turn off the power supply (F-500BAJ).
15) Replace the top and side panels in their correct positions. 16) Move the control switch to the "ICE" position. 17) Move the power switch to the "ON" position. 18) Replace the front panel in its correct position, then plug the appliance into the electrical outlet (F-300BAJ) or turn on the power supply (F-500BAJ).. 7. Removal and Replacement of Gear Motor 1) Drain the water from the evaporator. a) Remove the front panel, then move the power switch to the "OFF" position.
V. Maintenance The appliance must be maintained in accordance with the instruction manual and labels provided. Consult with your local Hoshizaki Certified Service Representative about maintenance service. WARNING • Only qualified service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the icemaker power switch or control switch with damp hands. • Before Servicing: Move the icemaker's power switch to the "OFF" position. Turn off the power supply.
A. Maintenance Schedule The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the appliance's environment, and local sanitation regulations. Maintenance Schedule Frequency Area Task Daily Scoop Bi-Weekly Monthly Air Filters External Water Filters Icemaker Exterior Clean the ice scoop using a neutral cleaner. Rinse thoroughly after cleaning. Inspect. Wash with warm water and neutral cleaner if dirty.
VI. Disposal The appliance contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.
VII. Technical Information We reserve the right to make changes in specifications and design without prior notice. A. Specification & Performance Data Sheets Note: The data in bold should be used for reference. 1. F-300BAJ Specification Sheet AC SUPPLY VOLTAGE AMPERES MAX. HACR BREAKER SIZE ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER SHAPE OF ICE ICE HARDNESS BIN CONTROL SYSTEM REFRIGERANT CHARGE Performance Data Sheet APPROXIMATE ICE PRODUCTION PER 24 HR. 115/60/1 7.
2. F-500BAJ Specification Sheet AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR OTHER MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER SHAPE OF ICE ICE HARDNESS BIN CONTROL SYSTEM REFRIGERANT CHARGE 115/60/1 115/60/1 10.5 RLA 54.5 LRA 115 V 2.4 FLA 1/4 HP 115 V 0.85A MAX 115 V 0.03 A 20 A 20 A 20 A 20 A 90/70°F 70/50°F 861 (5.05) 808 (3.62) 50 (12.0) 64 (12.
B. Wiring Diagrams 1.
2.
