Service Manual Modular Cubelet Serenity Series Models FS-1501MLJ-C with SRC-14J 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.................................................................................................. 5 I.
VII. Technical Information...................................................................................................... 56 A. Specification and Performance Data Sheets................................................................ 56 B. Wiring Diagrams........................................................................................................... 57 1. FS-1501MLJ-C........................................................................................................ 57 2.
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 FS • The icemaker requires an independent power supply of proper capacity. See the nameplate for electrical specifications. 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 fire. • THE ICEMAKER MUST BE GROUNDED. The icemaker is equipped with a NEMA 5-15 three‑prong grounding plug to reduce the risk of potential shock hazards.
NOTICE • Follow the instructions in this manual carefully to reduce the risk of costly water damage. • In areas where water damage is a concern, install in a contained area with a floor drain. • Install the appliance in a location that stays above freezing. Normal operating ambient temperature must be within 45°F to 100°F (7°C to 38°C). • Do not leave the icemaker on during extended periods of non-use, extended absences, or in sub-freezing temperatures.
I. Construction and Water/Refrigeration Circuit Diagram A. Construction 1.
2. Condensing Unit Top Panel High-Pressure Switch Compressor Condenser Fan Motors Headmaster (C.P.R.
3.
Water Supply Line Inlet Water Valve Overflow Gear Motor Evaporator Water Level Reservoir Float Switch Thermostatic Expansion Valve FS 11 Drier Liquid Line Safety Low-Pressure Switch Control Low-Pressure Switch Suction Line Shutoff Valve Suction Line Suction Line Service Valve Drain Outlet Drain Valve Fan Motors Strainer Liquid Line Liquid Line Shutoff Valve Service Valve Pump-Down Solenoid Valve Condenser Receiver High-Pressure Switch Headmaster (C.P.R.) Compressor SRC B.
Legend: BC1-bin control 1 (infrared sensor) BC2-bin control 2 (mechanical) CB-control board CCH-crankcase heater CLPS-control low-pressure switch Comp-compressor DC-drain cycle DT-drain timer DV-drain valve EH-evaporator heater (CB S1 dip switch 4 "ON") 3. 1-in-12 Drain Cycle & Restart (optional) 2. 1-in-1 Drain Cycle (CB S1 dip switch 4 "OFF") 5 or 30 sec. 5 min. (S1 Dip Switch 7) To bypass, press the "SERVICE" button after GM starts. 2.
BC1 activated 13 BC2 BC1 de-activated BC1 Green LED on BC1 Yellow LED off BC1-bin control 1 (infrared sensor) BC2-bin control 2 (mechanical) Comp-compressor FMR-fan motor-remote GM-gear motor LLV-liquid line valve (MLJ) SLV-suction line valve (MLJ) to "2. Ice Purge Cycle" in Icemaking and Drain Cycle Chart Note: If BC1 fails to shutdown the icemaker, BC2 opens and a 9-beep alarm sounds. See "II.D. Bin Control Check." 4. Icemaker Restart to "2.
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) 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). Check that both the 24VAC circuit fuse and the 115VAC GM fuse are good. Note: • When checking high voltage (115VAC), always choose a neutral (W) wire to establish a good neutral connection.
6) Startup – CB "POWER OK" LED is on. Plug the icemaker back into the electrical outlet, then move the power switch to the "ON" position. Move the control switch to the "ICE" position. CB "POWER OK" LED and IS (BC1) green LED turn on. Diagnosis CB "POWER OK" LED: If CB "POWER OK" LED is off, check for proper supply voltage (115VAC) input to CT. If 115VAC is not present, check the power switch and breaker. Next, check for proper 24VAC output voltage from CT. Check CB K8 #1 (W/R) to #2 (LBU) for 24VAC.
8) Ice Purge Cycle – "GM" LED is on. 30‑sec. GM delay timer terminates. GM, EH, 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.
Condensing Unit Diagnosis: Confirm that CLPS closes. Once CLPS closes, MC energizes, energizing Comp and FMR. If not, check condensing unit 208-230VAC power supply, breakers, disconnects. Next, confirm 115VAC from CLPS (BR) wire to neutral (W). If 115VAC is not present, check wiring connections and power supply. CLPS: When PDS is energized, CLPS closes when refrigeration circuit low-side pressure reaches 29 PSIG. If CLPS is open, check that refrigeration circuit low-side pressure has reached 29 PSIG.
10) Refill Cycle – "GM", "COMP", and "WTRIN" LEDs are on. LFS opens. WV energizes and FT starts. GM, CCR, EH, PDS, MC, Comp, and FMR 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-sec. 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 and PDS 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.
12) Shutdown a) BC1 (infrared sensor): When power is supplied to the icemaker, the green LED on BC1 turns on. The green LED remains on constantly. As ice fills the storage bin to the level of activating BC1, BC1 yellow LED turns on (flashing or steady). The yellow LED flashes when ice is at the outer limit of its range and turns steady as ice nears. After the yellow LED turns on (flashing or steady), BC1 shutdown delay timer (S1 dip switch 1, 2, 3) starts.
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.
4) 5VDC Output Checks: CB K9 Connector: Control Switch (CB K9 #1 and #2) (open contacts for icemaking, closed contacts for drain), Jumper (CB K9 #3 and #4), Compressor Control Relay (K9 #5 and #6). Float Switch (K8 #5 (common), #6 (upper), and #7 (lower)). When checking 5VDC control voltage, always place the red positive test lead from the multimeter to the CB white K5 pin closest to the CB red K4 connector. See Fig. 2.
c. Float Switch (LFS and UFS) – CB K8 #5 (BK) (common), CB K8 #6 (R) (upper), and CB K8 #7 (DBU) (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 (DBU) (lower) when FS is open. If 5VDC is present between CB K8 #5 (BK) and CB K8 #6 (R) (upper) or CB K8 #7 (DBU) (lower), FS is open.
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 black (BK) and neutral (W) at all times. If not, check 115VAC power supply wire connections from power switch.
• "GM" LED (X2 Relay) GM • "COMP" LED (X1 Relay) PDS • K9 Connector (5VDC) High-Pressure Switch Control Switch (not used on this model) #1 & #2 (white/black) #3 & #4 (yellow) Compressor Control Relay Circuit #5 & #6 (white/orange) • S2 "SERVICE" Button (Ice Purge Cycle Bypass) • K1 Connector (115VAC) 115VAC Input #3 (black) GM, EH, CCR #2 (white/black) • "FLUSH" LED (X3 Relay) (drain) DV • "WTRIN" LED (X4 Relay) WV • K8 Connector (24VAC and 5VDC) Control Transformer 24VAC Input #1 (white/red) (DRAIN)
D. Bin Control Check 1. Bin Control 1 (BC1) (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) Remove the front panel. 2) Move the power switch to the "OFF" position, then unplug the appliance from the electrical outlet. 3) Remove the control box cover and access CB. Confirm that S1 dip switch 1, 2, 3 are in the proper position for your application.
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 (flashing or steady). The yellow LED flashes when ice is at the outer limit of its range and turns steady as ice nears.
2. Bin Control 2 (BC2) (mechanical backup) Check When the spout cover is closed, BC2 is closed and the icemaker produces ice. With S1 dip switch 7 placed in the "ON" position, BC2 is used as a backup bin control safety. When BC1 fails to shut down the icemaker and ice fills the chute and disengages the spout cover, BC2 opens and CB immediately shuts down the icemaker and sounds a 9-beep alarm. 1) Move the power switch to the "OFF" position, then unplug the icemaker from the electrical outlet.
E. Power Switch and Control Switch The power switch and control switch are used to control the operation of this appliance. 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 (open), no power is supplied to the components. When in the "ON" (closed) 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.
F. Float Switch Check and Cleaning 1. Float Switch Check 1) Remove the front panel, then move the power switch to the "OFF" position. 2) Move the control switch to the "DRAIN" position. 3) Move the power switch to the "ON" position. 4) Allow the water to drain from the evaporator, then move the power switch to the "OFF" position and the control switch to the "ICE" position. 5) Unplug the appliance from the electrical outlet. 6) Remove the control box cover.
13) Replace CB K8 connector in its correct position. Replace the control box cover in its correct position. 14) Plug the appliance into the electrical outlet, then move the power switch to the "ON" position to start the automatic icemaking process. 15) Replace the front panel in its correct position. 2. Float Switch Cleaning Depending on local water conditions, scale may build up on FS. Scale on FS can cause inconsistent operation of UFS and LFS. In this case, both UFS and LFS should be cleaned and checked.
G. 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-FS a) Unplugged, off, blown fuse, or tripped breaker. b) Not within specifications. c) Loose connection. d) Bad contacts. Power Supply-SRC a) Off, tripped breaker b) Not within specifications.
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) No power to pump-down solenoid valve or not reading compressor control relay condition. Defective. 3. Pump-Down Solenoid Valve a) Defective. 4. Control Low-Pressure Switch a) Refrigerant pressure too low.
Shutdown 1. Bin Control 1 (infrared sensor) See "II.D. Bin Control Check." a) Dirty lens. b) Defective. c) Control board (no power to IS). 2. BC2 (Mechanical Backup) See "II.D. Bin Control Check." a) Defective. 3. Control Board a) Control board dip switches set incorrectly. b) In alarm. c) Defective. Drain Cycle 1. Drain Valve a) Screen or orifice clogged. b) Defective. 2. Control Board a) Defective.
III. Controls and Adjustments A. Control Board • A Hoshizaki exclusive control board is employed in Hoshizaki Modular Flakers. • All models are pre-tested and factory adjusted. • For a control board check procedure, see "II.C. Control Board Check." NOTICE • The control board is fragile; handle very carefully. • The control board contains integrated circuits, which are susceptible to failure due to static discharge.
1.
2. LED Lights and Audible Alarm Safeties At startup, CB green "POWER OK" LED turns on immediately to indicate proper control voltage and will remain on unless a control voltage problem occurs. For further details, see "II.B. Service Diagnosis.
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: S1 Dip Switch Model FS-1501MLJ-C S1 Dip Switch No.
2. BC1 (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 appliance is factory set for infrared sensor bin control operation. No adjustment is required. In the factory default position (S1 dip switch 7 in the on position), the gear motor delay after the upper float switch closes is 30 sec. WARNING! Do not place S1 dip switch 7 in the off position. This could lead to icemaker movement or ice overflow. S1 Dip Switch Setting Bin Control Application Gear Motor Delay No.
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. • Before Servicing: FS: Move the icemaker's power switch to the "OFF" position. Unplug the icemaker from the electrical outlet. SRC: Turn off the power supply to the remote condensing unit. Place the disconnect (if applicable) in the off position.
1. Refrigerant Recovery Using proper refrigerant practices, recover the refrigerant. Recover via the service valves. Store the refrigerant in an approved container. Do not discharge the refrigerant into the atmosphere. 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.
5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. See the rating label inside the icemaker for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets AHRI Standard 700 (latest edition) be used. 6) A liquid charge is required when charging an R-404A system (to prevent fractionation).
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 pre-applied threadlocker, apply Loctite 243 or equivalent threadlocker to seal bolt threads.
Removable Rubber Drip Pan Evaporator Assembly FS-1501MLJ-C Cutter Upper Bearing (pressed into auger) Extruding Head Auger Evaporator Heater Flange Seal Bolt O-Ring Drip Pan Socket Head Cap Screw and Split Lock Washer Mechanical Seal O-Ring Hex Bolt and Washer Lower Bearing (pressed into lower housing) Truss Head Screw w/Rubber Washer Lower Housing Spline Coupling Gear Motor Barrier Gear Motor Model Shown: FS-1501MLJ-C Socket Head Cap Screw and Split Lock Washer 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) Remove the front panel. Move the power switch to the "OFF" position, then unplug the unit from the electrical outlet. 2) Remove the top and side panels. 3) Remove the insulation strap, spout insulation, and spout. 4) Remove the bolt (if applicable) or cutter from the auger and lift off the cutter and washer (if applicable). .
IMPORTANT! Seal Bolt Removal and Installation Instructions: 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. • Torque for FS-1501 and Larger: 25.8 ft-lb/35 N·m Tighten 2 times. Allow at least 5 sec. in between each tightening. 3. Removal and Replacement of Extruding Head 1) Drain the water from the evaporator.
7) Replace the removed parts in the reverse order of which they were removed. Note: Be sure to use new seal bolts. See "Seal Bolt Removal and Installation Instructions" above. 8) Replace the top and side panels in their correct positions. 9) Move the control switch to the "ICE" position. 10) Plug the unit into the electrical outlet, then move the power switch to the "ON" position to start the automatic icemaking process. 11) Replace the front panel in its correct position. 5.
12) Make sure the lower mechanical seal is in place, then place the evaporator in position. Secure the evaporator to the lower housing using the socket head cap screws and split lock washers. 13) Remove the drier, then place the new drier in position. 14) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG. 15) Use an electronic leak detector or soap bubbles to check for leaks.
8) Remove the O-ring and mechanical seal from the housing. If only replacing the mechanical seal, proceed to step 15. NOTICE! To help prevent water leaks, be careful not to damage the surfaces of the O‑ring or mechanical seal. NOTICE To help prevent water leaks, be careful not to damage the surfaces of the O‑ring or mechanical seal. 6b. Lower Housing 9) Remove the hex bolts w/washers securing the lower housing to the gear motor and remove the lower housing from the gear motor.
6) Disconnect the gear motor wiring, then remove the gear motor. 7) Remove the gear motor bracket and spline coupling from the old gear motor and place on the new gear motor. 8) Install the new gear motor and reconnect the electrical wires. 9) Replace the removed parts in the reverse order of which they were removed. 10) Replace the top and side panels in their correct positions. 11) Move the control switch to the "ICE" 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: FS: Move the icemaker's power switch to the "OFF" position.
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 Monthly External Water Filters Icemaker Exterior Clean the ice scoop using a neutral cleaner. Rinse thoroughly after cleaning. Check for proper pressure and change if necessary.
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 A. Specification and Performance Data Sheets 1. FS-1501MLJ-C with SRC-14J Specification Sheet AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER ICE HARDNESS BIN CONTROL SYSTEM REFRIGERANT CHARGE DESIGN PRESSURE Performance Sheet APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. (TOTAL) gal.
B. Wiring Diagrams 1. FS-1501MLJ-C DIP SWITCH S1 No. 1 FS-1501-MLJ-C ON No. 2 No. 3 OFF No. 4 OFF No. 5 OFF No. 6 OFF No. 7 No. 8 ON ON OFF No. 9 No. 10 OFF OFF WIRE COLOR CODE BK (GR) W BK BR DBU GR GY LBU O P R 115-120/60/1 GND N L W BK POWER SWITCH W BK BLACK BROWN DARK BLUE GREEN GRAY LIGHT BLUE ORANGE PINK RED W/O W/O 2 W/O 3 4 W/O 5 6 R 7 8 W PUMP-DOWN SOLENOID VALVE (BK,T1) W/O W GY BK W/O GY CAP.
2. SRC-14J Condensing Unit 208-230/60/1 (3 WIRE WITH NEUTRAL) L2 L1 BK N W BR BR BR START RELAY R START CAP (145-174MFD) BK BR 1 RUN CAP. (30 MFD) R DBU R BR L3 T3 BR L2 T2 R BK L1 T1 BK BR COM (BK) DBU DBU R NO (BK) (W) BK W W BK CAP 2 10 MFD W W BK W W O O O ** LOW-PRESS. SWITCH 2 Cut-in 29±00.
