Hoshizaki F-800MAF, Service Manual

Page 1: ...SERVICE MANUAL ISSUED JAN 20 1999 MODEL HOSHIZAKI MODULAR FLAKER F 800MAF C F 800MWF C NO 73080 REVISED DEC 17 2003 ...

Page 2: ...tionoftheproblem IMPORTANT Only qualified service technicians should attempt to service or maintain this icemaker No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should the reader have any questions or concerns w...

Page 3: ... F 800MAF C F 800MWF C 17 3 SEQUENCE OF ELECTRICAL CIRCUIT 18 4 TIMING CHART 28 5 PERFORMANCE DATA 31 F 800MAF 31 F 800MWF 32 F 800MAF C 33 F 800MWF C 34 IV ADJUSTMENT OF COMPONENTS 35 1 ADJUSTMENT OF WATER REGULATING VALVE WATER COOLED MODEL ONLY 35 2 ADJUSTMENT OF FLAKE SIZE 36 Please review this manual It should be read carefully before the icemaker is serviced or maintenance operations are per...

Page 4: ...MENT OF EXPANSION VALVE 45 6 REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE WATER COOLED MODEL ONLY 46 7 REMOVAL AND REPLACEMENT OF CONDENSING PRESSURE REGULATOR C P R REMOTE AIR COOLED MODEL ONLY 47 8 REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY 48 9 REMOVAL AND REPLACEMENT OF FAN MOTOR 52 10 REMOVAL AND REPLACEMENT OF CONTROL WATER VALVE 52 11 REMOVAL AND REPLACEMENT OF FLUSH WATER VALVE 53...

Page 5: ...90 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger 1 6 HP Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Bin Control Proximity Sw COMPRESSOR Hermetic Model RS55 C1E PAA CONDENSER Air cooled Fin and tube type EVAPORATOR Copper Tube...

Page 6: ...ction WATER SUPPLY Inlet 1 2 FPT Cond Inlet 1 2 FPT DRAIN Outlet 3 4 FPT Cond Outlet 3 8 18 NPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger 1 6 HP Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL Automatic Water Regulator BIN CONTROL SYSTEM Mechanical Bin Control Proximity Sw COMPRESSOR Hermetic Model RS55 C1E PAA CONDENSER Water cooled Tube in tube typ...

Page 7: ...TIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 FPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger 1 6 HP Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Bin Control Proximity Sw COMPRESSOR Hermetic Model RS55 C1E PAA CONDENSER Air cooled Fin and tube type EVAPORATOR Copper Tube on Cylinder...

Page 8: ...nection WATER SUPPLY Inlet 1 2 FPT Cond Inlet 1 2 FPT DRAIN Outlet 3 4 FPT Cond Outlet 3 8 18 NPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger 1 6 HP Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL Automatic Water Regulator BIN CONTROL SYSTEM Mechanical Bin Control Proximity Sw COMPRESSOR Hermetic Model RS55 C1E PAA CONDENSER Water cooled Tube in tube t...

Page 9: ...9 2 CONDENSER UNIT URC 6F ...

Page 10: ...8 x 454 mm REFRIGERANT CHARGE R404A 1 lb 14 oz 850 g WEIGHT Net 61 lbs 28 kg Shipping 68 lbs 31 kg CONNECTIONS REFRIGERANT One Shot Couplings Aeroquip ELECTRICAL Permanent Connection CONDENSER Air cooled HEAD PRESSURE CONTROL Condensing Pressure Regulator AMBIENT CONDITION Min 20 F Max 122 F 29 C to 50 C Outdoor use ...

Page 11: ...INFORMATION 1 CONSTRUCTION F 800MAF C Water Supply Inlet Junction Box Condenser Fan Motor Compressor Drier Control Water Valve Bin Control Ice Chute Evaporator Expansion Valve Flush Water Valve Control Box Gear Motor ...

Page 12: ...12 F 800MWF C Water Supply Inlet Junction Box Water Regulator Compressor Drier Control Water Valve Bin Control Ice Chute Evaporator Expansion Valve Flush Water Valve Control Box Gear Motor ...

Page 13: ...l but not with the Parts List PRESSURE SWITCH CONNECTOR START CAPACITOR RUN CAPACITOR WATER CONTROL RELAY FLUSH TIMER TRANSFORMER GEAR MOTOR RELAY GEAR MOTOR CAP FLUSH ICE FAN MOTOR CAP GEAR MOTOR PROTECT RELAY STARTER CONTROL TIMER FUSE GEAR MOTOR FUSE POWER SWITCH FLUSH SWITCH CIRCUIT PROTECT RELAY ...

Page 14: ...CTOR START CAPACITOR RUN CAPACITOR WATER CONTROL RELAY TRANSFORMER GEAR MOTOR RELAY FLUSH ICE GEAR MOTOR PROTECT RELAY STARTER CONTROL TIMER FLUSH SWITCH POWER SWITCH FUSE FUSE GEAR MOTOR FLUSH TIMER CIRCUIT PROTECT RELAY GEAR MOTOR CAP ...

Page 15: ...15 III TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERATION CIRCUIT F 800MAF C ...

Page 16: ...16 F 800MWF C ...

Page 17: ...17 2 WIRING DIAGRAMS F 800MAF C F 800MWF C ...

Page 18: ...18 3 SEQUENCE OF ELECTRICAL CIRCUIT a When Power Switch is moved to ON position and Flush Switch to ICE position water starts to be supplied to Reservoir ...

Page 19: ...19 b When Reservoir has been filled Gear Motor starts immediately ...

Page 20: ...20 c Compressor starts about 60 sec after Gear Motor starts ...

Page 21: ...21 d Bin Control operates and about 6 sec later Compressor and Gear Motor stop simultaneously ...

Page 22: ...22 e Low Water Except Water cooled Model ...

Page 23: ...23 f Low Water Water cooled Model or Dirty Air Filter Air cooled Model Pressure Switch to OPEN Compressor and Gear Motor operates intermittently ...

Page 24: ...24 g When Flush Switch is moved to FLUSH position Flush Water Valve opens and flushes Reservoir and Evaporator ...

Page 25: ...25 h When Flush Timer operates for 15 min every 12 hours ...

Page 26: ... 208 230V are supplied to Circuit Protect Relay it protects the circuit from miswiring If the power supply is properly connected the contact of Circuit Protect Relay does not move even when the coil is energized ...

Page 27: ...27 j When input voltage is too low Less than 70 Gear Motor Fuse 1 5A is blown causing the Compressor and Gear Motor to turn off immediately ...

Page 28: ...ER 4 WATER CONTROL RELAY 5 CONTROL WATER VALVE 6 FLUSH TIMER 7 FLUSH SWITCH 8 FLUSH WATER VALVE 9 BIN CONTROL 10 GEAR MOTOR RELAY 11 GEAR MOTOR 12 FAN MOTOR 13 COMPRESSOR 14 PRESSURE SWITCH ON OFF ON OFF ON OFF ON OFF ON OFF 1 2 2 3 FLUSH ICE ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF 1 sec 60 sec 6 sec 1 sec 60 sec UPPER LOWER BOTTOM 4 TIMING CHART ...

Page 29: ...WITCH 8 FLUSH WATER VALVE 9 BIN CONTROL 10 GEAR MOTOR RELAY 11 GEAR MOTOR 12 FAN MOTOR 14 PRESSURE SWITCH ON OFF ON OFF ON OFF ON OFF ON OFF 1 2 2 3 FLUSH ICE ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF UPPER LOWER BOTTOM LOW WATER FLUSH TIMER 21 min every 12 hr 150 sec 1 sec 150 sec 90 sec 60 sec 90 sec 60 sec 1 sec 13 COMPRESSOR ...

Page 30: ... SWITCH 8 FLUSH WATER VALVE 9 BIN CONTROL 10 GEAR MOTOR RELAY 11 GEAR MOTOR 12 FAN MOTOR 14 PRESSURE SWITCH ON OFF ON OFF ON OFF ON OFF ON OFF 1 2 2 3 FLUSH ICE ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF UPPER LOWER BOTTOM FLUSH SWITCH PRESSURE SWITCH FLUSH ICE OFF ON 150 sec 1 sec 90 sec 60 sec 13 COMPRESSOR 1 sec 1 sec 60 sec ...

Page 31: ...69 261 64 242 gal day l day 100 61 231 59 221 55 206 EVAPORATOR OUTLET TEMP 70 16 9 17 8 17 8 F C 80 18 8 18 8 19 7 90 21 6 19 7 21 6 100 22 5 23 5 23 5 HEAD PRESSURE 70 221 15 5 221 15 5 221 15 5 80 254 17 8 254 17 8 254 17 8 90 286 20 1 286 20 1 286 20 1 PSIG kg cm G 100 325 22 8 325 22 8 325 22 8 SUCTION PRESSURE 70 35 2 5 35 2 5 35 2 5 PSIG kg cm G 80 38 2 7 38 2 7 38 2 7 90 41 2 9 41 2 9 41 2...

Page 32: ...1 6 22 6 21 6 F C 80 22 6 22 6 22 6 90 21 6 22 6 22 6 100 23 5 23 5 22 5 HEAD PRESSURE 70 265 18 6 267 18 8 266 18 7 80 267 18 8 266 18 7 265 18 7 90 266 18 7 266 18 7 265 18 7 PSIG kg cm G 100 267 18 8 269 18 9 268 18 8 SUCTION PRESSURE 70 37 2 6 37 2 6 37 2 6 PSIG kg cm G 80 38 2 6 37 2 6 38 2 6 90 38 2 6 38 2 6 38 2 7 100 39 2 7 39 2 7 39 2 7 WATER FLOW FOR CONDENSER 44 gal h AT 90 F WT 70 F PR...

Page 33: ...4 242 gal day l day 100 61 231 59 221 55 206 EVAPORATOR OUTLET TEMP 70 16 9 17 8 17 8 F C 80 18 8 18 8 19 7 90 21 6 19 7 21 6 100 22 5 23 5 23 5 HEAD PRESSURE 70 221 15 5 221 15 5 221 15 5 80 254 17 8 254 17 8 254 17 8 90 286 20 1 286 20 1 286 20 1 PSIG kg cm G 100 325 22 8 325 22 8 325 22 8 SUCTION PRESSURE 70 35 2 5 35 2 5 35 2 5 PSIG kg cm G 80 38 2 7 38 2 7 38 2 7 90 41 2 9 41 2 9 41 2 9 100 4...

Page 34: ...21 6 22 6 21 6 F C 80 22 6 22 6 22 6 90 21 6 23 5 22 6 100 23 5 23 5 23 5 HEAD PRESSURE 70 265 18 6 267 18 8 266 18 7 80 267 18 8 266 18 7 265 18 7 90 266 18 7 266 18 7 265 18 7 PSIG kg cm G 100 267 18 8 269 18 9 268 18 8 SUCTION PRESSURE 70 37 2 6 37 2 6 37 2 6 PSIG kg cm G 80 38 2 6 37 2 6 38 2 6 90 38 2 6 38 2 6 38 2 7 100 39 2 7 39 2 7 39 2 7 WATER FLOW FOR CONDENSER 46 gal h AT 90 F WT 70 F P...

Page 35: ...pare a thermometer to check the condenser drain temperature 2 Rotate the Adjustment Screw by using a flat blade screwdriver so that the pressure gauge shows 260 PSIG R 404A models F type or the thermometer reads 100 104 F in 5 minutes after the icemaking process starts When the pressure exceeds 260 PSIG or the condenser drain temperature exceeds 104 F rotate the Adjustment Screw counterclockwise 3...

Page 36: ...ing procedures 1 Remove the Bolt and the Cutter Head 2 The Cutter Head has two holes one for fine flake and the other for coarse flake size The unit is shipped from the factory in the fine flake position 3 Place the Cutter Head so that the Pin on the top of the Auger fits into the selected hole 4 Secure the Cutter Head by the Bolt FINE COARSE ...

Page 37: ... 2 Wait till water is supplied j Plug and Receptacle Control Box 1 Disconnected 1 Connect 2 Terminal out of Plug or Receptacle 2 Insert Terminal back in position 2 Water flow does not stop and the icemaker will not start a Water Control Relay 1 Contact fused 1 Replace 2 Coil winding opened 2 Replace b Float Switch 1 Bad contacts 1 Check for continuity and replace 2 Float does not move freely 2 Cle...

Page 38: ...e drier 8 Bad contacts 8 Check for continuity and replace 9 Loose connections 9 Tighten 6 Gear Motor starts but Compressor will not start or operates intermittently a X2 Relay on Control Timer 1 Bad contacts 1 Replace Check for continuity and replace 2 Coil winding opened 2 Replace Timer b Starter 1 Bad contacts 1 Check for continuity and replace 2 Coil winding opened 2 Replace 3 Loose Connections...

Page 39: ...condenser water temperature too warm 2 Get cooler 3 Condenser water pressure too low or off Water cooled model only 3 Check and get recommended pressure 4 Fan rotating too slow 4 See 3 1 a Fan Motor 5 Water Regulating Valve clogged Water cooled model only 5 Clean 6 Condensing unit out of order 6 Check condensing unit c Expansion Valve not adjustable 1 Low side pressure too low 1 Replace 2 Low side...

Page 40: ...Use SCALE AWAY or LIME A WAY solution to clean periodically If the water is found hard by testing install a softener 2 Overflow from Reservoir Water does not stop a Water Supply 1 Water pressure too high 1 Install a pressure Reducing Valve b Control Water Valve 1 Diaphragm does not close 1 Clean or replace c Float Switch 1 Bad contacts 1 Check for continuity and replace 3 Gear Motor Fuse blown fre...

Page 41: ...me as those for current refrigerants However the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils 2 Turn on the Vacuum Pump Never allow the oil in the Vacuum Pump to flow backward 3 Allow the Vacuum Pump to pull down to a 29 9 Hg vacuum Evacuating period de pends on pump capacity IMPORTANT Ensure all components fasteners and thumbsc...

Page 42: ... liquid charge through the Low side access port with the unit running 9 Close the two Refrigerant Access Valves and disconnect the Hoses and Service Manifold 10 Cap the Access Valves to prevent a possible leak 2 BRAZING DANGER 1 Refrigerant R 404A itself is not flammable at atmospheric pressure and temperatures up to 176 F 2 Refrigerant R 404A itself is not explosive or poisonous However when expo...

Page 43: ...g equipment WARNING When repairing a refrigerant system be careful not to let the burner flame contact any electrical wires or insulation 5 Remove the Bolts and Rubber Grommets 6 Slide and remove the Compressor Unpack the new Compressor package Install the new Compressor 7 Attach the Rubber Grommets of the prior Compressor 8 Sandpaper the Discharge Suction and Access Pipes 9 Place the Compressor i...

Page 44: ...r all other repairs or replacement have been made 1 Turn off the power supply and remove the panels 2 Recover the refrigerant and store it in an approved container if required by an applicable law 3 Remove the Drier using brazing equipment 4 Install the new Drier with the arrow on the Drier in the direction of the refrigerant flow Use nitrogen gas at the pressure of 3 4 PSIG when brazing the tubin...

Page 45: ...alve using brazing equipment 5 Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 3 4 PSIG WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 6 Install the new Drier 7 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 8 Evacuate the system Charge it with refrigerant Fo...

Page 46: ...ube using brazing equipment 4 Disconnect the Flare connections of the valve 5 Remove the screws and the valve from the Bracket 6 Install the new valve and braze the Capillary Tube 7 Install the new Drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 Connect the Flare connections 10 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant ...

Page 47: ...and store it in an approved container 4 Remove the C P R using brazing equipment 5 Braze the new C P R with nitrogen gas flowing at the pressure of 3 4 PSIG WARNING Always protect the C P R body by using a damp cloth to prevent the C P R from overheating Do not braze with the C P R body exceeding 250 F 6 Install the new Drier in the icemaker 7 Check for leaks using nitrogen gas 140 PSIG and soap b...

Page 48: ...f the Cutter 9 Remove the Rubber O ring and the Nylon Ring at the top of the Evaporator EXTRUDING HEAD 10 Remove the four Socket Head Cap Screws and lift off the Extruding Head 11 Replace the Bearing inside the Extruding Head if it exceeds the wear tolerance of 0 02 or is scratched Note Replacing the Bearing requires a bearing press adaptor If it is not available replace the whole Extruding Head A...

Page 49: ... Screws securing the Evaporator with the Bearing Lower 19 Lift off the Evaporator BEARING LOWER AND MECHANICAL SEAL 20 The Mechanical Seal consists of two parts One moves along with the Auger and the other is fixed on the Bearing Lower If the contact surfaces of these two parts are worn or scratched the Mechanical Seal may cause water leaks and should be replaced 21 Remove the O ring on the Bearin...

Page 50: ...en replacing the Evaporator a Braze the new Evaporator with nitrogen gas flowing at the pressure of 3 4 PSIG b Replace the Drier c Check for leaks using nitrogen gas 140 PSIG and soap bubbles d Evacuate the system Charge it with refrigerant For the air cooled and water cooled models see the Nameplate for required refrigerant charge and type For the remote air cooled models see the label on the Con...

Page 51: ...Mechanical Seal O ring Bearing Lower Bolt Washer Coupling Spline Rubber O ring Nylon Ring Bolt Washer Cutter Extruding Head Washer Socket Head Cap Screw Evaporator Washer Socket Head Cap Screw Barrier Gear Motor ...

Page 52: ... Turn off the power supply remove the panels and close the Water Supply Line Shut off Valve 2 Disconnect the Terminals from the Control Water Valve 3 Loosen the Fitting Nut on the Control Water Valve Inlets and remove the Control Water Valve Do not lose the Packings inside the Fitting Nut 4 Remove the Water Supply Hose from the Control Water Valve 5 Install the new Control Water Valve 6 Assemble t...

Page 53: ...et 5 Remove the Drain Pipe from the Flush Water Valve 6 Connect the Drain Pipe to the new Flush Water Valve and place the valve in position 7 Connect the Hose to the Flush Water Valve and secure it with the Clamp 8 Pour water into the Reservoir and check for water leaks on the Flush Water Valve 9 Open the Water Supply Line Shut off Valve and turn on the power supply 10 Move the Flush Switch to the...

Page 54: ...peratures using air or carbon dioxide Shut off the icemaker until the proper ambient temperature is resumed Air cooled and Remote Air cooled Models 1 Run the icemaker with the Water Supply Line Shut off Valve closed 2 Open the Drain Valve and blow out the water inlet line by using air pressure 3 Turn off the power supply 4 Remove the Front Panel 5 Move the Flush Switch on the Control Box to the FL...

Page 55: ...2 Turn on the power supply and wait for 20 seconds 3 Close the Water Supply Line Shut off Valve 4 OpentheDrainValveandquicklyblowthewatersupplylinefromtheDrainValvetodrain water in the Condenser 5 Follow the above steps 3 through 11 in Air cooled and Remote Air cooled Models ...

Page 56: ...d sanitizing solution This will prevent irritation in case the solution contacts with skin STEP 1 Dilute the solutions with water as follows Cleaning solution 4 8 fl oz of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 0 8 gal of water This is a minimum amount Make more solution if necessary Sanitizingsolution 2 5 fl oz of a 5 25 sodium hypochlorite solution c...

Page 57: ...he Flush Switch to the ICE position 13 Replace the Top Panel and the Front Panel in their correct position 14 Allow the icemaker to set for about 10 minutes before the operation Then turn on the power supply and make ice using the solution until the icemaker stops icemaking 15 Remove the Front Panel 16 Move the Flush Switch to the FLUSH position to drain the cleaning solution 17 Move the Flush Swi...

Page 58: ...e sanitizing solution 11 Move the Flush Switch to the ICE position 12 Replace the Front Panel in its correct position 13 Open the Water Supply Line Shut off Valve and supply water to the Reservoir 14 Turn off the power supply when the Gear Motor starts 15 Drain out all water from the water line See 4 through 7 in STEP 2 16 Move the Flush Switch to the ICE position STEP 4 Use the sanitizing solutio...

Page 59: ...and Activator 8 Remove the three Thumbscrews and the Spout 9 Remove the Rubber O ring and Nylon Ring at the top of the Cylinder 10 Soak or wipe the removed parts 11 Rinse these parts thoroughly IMPORTANT If the solution is left on these parts they will rust 12 Replace the removed parts and the panels 13 Turn on the power supply and run the icemaker 14 Turn off the power supply after 30 minutes 15 ...

Page 60: ...efrequentinspectionandmaintenancearerecommended Consult with your local distributor about inspection and maintenance service Toobtainthenameandphonenumberofyourlocaldistributor call Hoshizaki Technical Support at 1 800 233 1940 1 Stainless Steel Exterior To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or ...

Page 61: ... cleaning 3 Air Filter Air cooled model only Aplasticmeshairfilterremovesdirtordustfromtheair andkeepstheCondenserfrom getting clogged As the filter gets clogged the icemaker s performance will be reduced Check the filter at least twice a month When clogged use warm water and a neutral cleaner to wash the filter 4 Condenser Except water cooled model Check the Condenser once a year and clean if req...