Transcript
CONTENTS
PAGE
I. SPECIFICATIONS ------------------------------------------------------------------------------------1. DIMENSIONS/CONNECTIONS ----------------------------------------------------------------2. SPECIFICATIONS --------------------------------------------------------------------------------[a] FM-1000ALE ----------------------------------------------------------------------------------[b] FM-1000ALF ----------------------------------------------------------------------------------[c] FM-1000ALE-N -------------------------------------------------------------------------------[d] FM-1000ALF-N --------------------------------------------------------------------------------
1 1 2 2 3 4 5
II. GENERAL INFORMATION -------------------------------------------------------------------------1. CONSTRUCTION ---------------------------------------------------------------------------------2. OPERATION - How it works --------------------------------------------------------------------3. TIMER BOARD ------------------------------------------------------------------------------------[a] SOLID-STATE CONTROL ------------------------------------------------------------------[b] TIMER BOARD --------------------------------------------------------------------------------[c] SEQUENCE ------------------------------------------------------------------------------------
6 6 7 8 8 8 9
III. INSTALLATION INSTRUCTIONS ----------------------------------------------------------------- 12 1. UNPACKING --------------------------------------------------------------------------------------- 12 2. LOCATION ------------------------------------------------------------------------------------------ 13 3. INSTALLATION ------------------------------------------------------------------------------------ 14 4. ELECTRICAL CONNECTIONS ---------------------------------------------------------------- 15 5. WATER SUPPLY AND DRAIN CONNECTIONS ------------------------------------------- 16 IV. OPERATING INSTRUCTIONS ------------------------------------------------------------------- 18 1. START UP ------------------------------------------------------------------------------------------ 18 2. PREPARING THE ICEMAKER FOR LONG STORAGE --------------------------------- 19 V. MAINTENANCE ------------------------------------------------------------------------------------- 21 1. PERIODICAL CLEANING ----------------------------------------------------------------------- 21 2. CLEANING OF WATER SYSTEM ------------------------------------------------------------- 22 VI. TECHNICAL INFORMATION --------------------------------------------------------------------- 26 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT ----------------------------------------- 26 2. WIRING DIAGRAM ------------------------------------------------------------------------------- 27 3. DIFFERENCE BETWEEN -ALE AND -ALF ------------------------------------------------ 28 4. TIMING CHART ------------------------------------------------------------------------------------ 29 [a] PRINCIPLE OF OPERATION -------------------------------------------------------------- 29 [b] FLUSH SWITCH ------------------------------------------------------------------------------ 29 [c] PROTECTORS -------------------------------------------------------------------------------- 30 VII. SERVICE DIAGNOSIS---------------------------------------------------------------------------- 31 1. NO ICE PRODUCTION -------------------------------------------------------------------------- 31 2. LOW ICE PRODUCTION ------------------------------------------------------------------------ 33 3. OTHERS -------------------------------------------------------------------------------------------- 33
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VIII. REMOVAL AND REPLACEMENT OF COMPONENTS --------------------------------- 35 1. SERVICE FOR REFRIGERANT LINES ----------------------------------------------------- 35 [a] REFRIGERANT RECOVERY -------------------------------------------------------------- 35 [c] EVACUATION --------------------------------------------------------------------------------- 35 2. BRAZING ------------------------------------------------------------------------------------------- 35 3. EXPANSION VALVE ----------------------------------------------------------------------------- 36 4. EVAPORATOR ASSEMBLY ------------------------------------------------------------------- 37 5. CONTROL WATER VALVE --------------------------------------------------------------------- 41 6. FLUSH WATER VALVE ------------------------------------------------------------------------- 41
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U2CM4779901
I. SPECIFICATIONS 1. DIMENSIONS/CONNECTIONS
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II. GENERAL INFORMATION 1. CONSTRUCTION
Spout Control
Bin Control
Control Box
Expansion Valve Evaporator Pressure Regulator Flush Water Valve
Solenoid Valve
Fan Motor
Junction Box
Water Supply Inlet Evaporator Control Water Valve
Reservoir
Ice Chute
Gear Motor
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2. OPERATION - How it works Water flows from the potable water source through the water supply tap, enters at the water inlet fitting and on to the Water Supply Assembly. The Water Supply Assembly functions to maintain a constant water level inside the Evaporator Assembly. Water from the water supply enters at the bottom of the Evaporator and changes into ice by heat-exchanging refrigerant from the Condensing Assembly. A stainless steel Auger inside the Evaporator is direct-driven by the Gear Motor, and the rotating Auger carries the ice upward to the end of the Auger, where excess water is pressed out of the ice, as the ice is extruded and broken into flake ice by the Cutter, or compressed into cubelet ice by the Extruding Head, and then pushed out into the Ice Storage Bin through the Ice Chute. Moving the Flush Switch on the Control Box to the “ICE” position and the Power Switch to the “ON” position starts an automatic and continuous icemaking process. When the Ice Storage Bin is filled with ice, the Bin Control Switch, located on the top of the Ice Storage Bin, stops the icemaking process. As the ice is taken out of the Storage Bin, the Bin Control Switch gets reset automatically and restarts the icemaking process. A water solenoid valve, for flushing the Reservoir and the Evaporator (Water System), is provided between the Evaporator and the drain outlet. The Flush Water Valve is controlled by a timer which signals to open the Water Valve automatically for 15 minutes every 12 hours, when the Flush Switch on the Control Box is manually moved to the “FLUSH” position.
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3. TIMER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in FM-1000ALE(-N) and FM1000ALF(-N) modular icemakers. 2) A Printed Circuit Board (hereafter called “Timer Board”) includes a stable and high-quality control system. 3) No adjustment is required.
[b] TIMER BOARD
CAUTION 1. Fragile, handle very carefully. 2. A timer board contains CMOS (Complementary Metal-Oxide Semiconductor) integrated circuits, which are susceptible to failure due to static discharge. It is especially important to use an anti-static wrist strap when handling or replacing the board. 3. Do not touch the electronic devices on the board or at the back of the board to prevent damage to the board. 4. Do not change wiring and connections. Especially, never misconnect terminals. 5. Do not fix the electronic devices or parts on the board in the field. Always replace the whole board assembly when it goes bad.
The icemaker is controlled by the Timer Board for the following purposes: 1) To prevent the Gear Motor and the Compressor from starting or stopping simultaneously. 2) To reduce remaining ice in the refrigeration casing. 3) To protect the unit in case of low water and low water pressure. 4) To protect the unit in case the Bin Control causes chattering.
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Fig. 1
[c] SEQUENCE
Fig. 2
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CONTROL (CTL)
PROTECT (PRT)
X1 RELAY (GEAR MOTOR) X2 RELAY (COMPRESSOR)
PART CODE MODEL RATING T1 T2 T3 T4 T5 T6
437305-01 H2AA144C01 24 VAC 50/60Hz 60 •}15 sec. 90 •}22 sec. 150 •}45 sec. Max. 1 sec. 6.7 •}4.5 sec. 6.7 •}4.5 sec.
Fig. 3
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Functions of Terminals 1) Terminals 1, 2 Power supply AC 24V. 2) Terminals 3, 4 Control X1 (GM) and X2 (CM) Relays. When closed, energize X1 (GM) in 1 sec. and X2 (CM) in 60 sec. When opened, de-energize X1 (GM) in 150 sec. and X2 (CM) in 90 sec. 3) Terminals 5, 6 Control X1 (GM) and X2 (CM) Relays. When opened, de-energize X1 (GM) and X2 (CM) in 7 sec. When closed, energize X1 (GM) in 7 sec. and X2 (CM) in 60 sec. 4) Terminals 7, 8, 9 X1 (GM) contacts. 8 is a movable contact, 7 is a make contact, and 9 is a break contact. 5) Terminals 10, 11 Control X2 (CM) Relay. When opened, de-energize X2 (CM) immediately. When closed, energize X2 (CM) immediately.
Note: 1. X2 Relay is a single pole, normally open relay, and its terminals are mounted on the relay itself. 2. The above operation times are median. See Fig. 3 for details.
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III. INSTALLATION INSTRUCTIONS WARNING The installation must be carried out by qualified personnel, in accordance with current regulations, according to the manufacturer’s instructions.
1. UNPACKING WARNING Children should not be allowed in reach of the packaging elements (plastic bags and expanded polystyrene) as they are potential sources of danger.
CAUTION Remove shipping carton, tape(s) and packing. If packing material is left in the icemaker, it will not work properly.
Note: 1. This icemaker needs a Storage Bin. The recommended Storage Bin is HOSHIZAKI ICE STORAGE BIN, Model B-500SD(PD), B-700SD(PD) with Top Kit - 14C, or B900SD(PD) with Top Kit - 22C. 2. This icemaker is designed to be connected with R22 (FM-1000ALE) or R404A (FM-1000ALF) multi compressor rack system. 1) After removing the packaging, make sure that the icemaker and the Storage Bin are in good condition. If in doubt, please do not use the equipment. See the instruction sheet attached to the Storage Bin for its unpacking and installation guidelines. 2) Remove the shipping tape holding the Front Panel. 3) Remove the Front, Top and Side Panels. See Fig. 4. 4) Remove the package of accessories, and check the contents: a) Installation Kit Inlet Hose 1 Outlet Hose 1 1/2-3/4 Nipple 1 3/4-3/4 Nipple 1 b) Scoop 1 c) Mounting Bracket 2
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5) Remove the protective plastic film from the panels. If the icemaker is exposed to the sun or to heat, remove the film after the icemaker cools. Top Panel
Side Panel Front Panel
Front Panel: Top Panel: Side Panel:
Remove the screw. Lift up and pull toward you. Remove the screw. Lift off. Remove the screw. Pull slightly toward you and lift up.
Fig. 4 2. LOCATION WARNING 1. This icemaker is not intended for outdoor use. Normal operating ambient temperature should be within 5°C to 40°C. Normal operating water temperature should be within 5°C to 35°C. Operation of the icemaker, for extended periods, outside of these normal temperature ranges may affect production capacity. 2. The icemaker should not be located next to ovens, grills or other high heat producing equipment. 3. The location should provide a firm and level foundation for the equipment. 4. Allow 15 cm clearance at rear and sides for proper air circulation and ease of maintenance and/or service should they be required. Allow 60 cm clearance on top to allow for removal of the Auger. 5. This appliance is not suitable for installation in an area where a water jet could be used and where dripping is not allowed. 6. Do not place anything on top of the icemaker or in front of the Louver.
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3. INSTALLATION * This icemaker requires refrigeration, power, water and drainage connections (sections 3, 4 and 5 of this manual). DO NOT attempt to start this unit until all connections/services are connected.
Bottom Plate
* Incorrect installation can cause harm to people, animals or things, for which the manufacturer cannot be held responsible.
Adjustable Legs
1) Fully screw in the four legs provided (bin accessory) into the Storage Bin underside. See Fig. 5.
Fig. 5
2) Position the Storage Bin in the selected permanent site. 3) Place the icemaker on top of the Storage Bin by holding the bottom. 4) Secure the icemaker to the Storage Bin, by using the two mounting brackets and two bolts provided. See Fig. 6. 5) Seal the seam between the icemaker and the Storage Bin with food grade sealant. 6) Refit the Side Panels in their correct position.
Icemaker
Bin Bolt Mounting Bracket
Fig. 6
7) Adjust the four legs on the bottom (adjustable from 0 to 25.4 mm) to have the icemaker perfectly horizontal. Use the spirit level. See Fig. 7. 8) The icemaker must be connected to the liquid and suction lines of the main pipework system using two copper tubes of sufficient lengths and sizes directed to the rear of the icemaker for connection to the pre-fitted internal copper tubes. Both tubes should be insulated separately. Note: Sizes for the interconnecting pipes from the icemaker to the main system should be 3/8” OD for the liquid line 14
Adjust legs
Fig. 7
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Adjustable Close - Clockwise Open - Counterclockwise
and 5/8” OD for the suction line up to a maximum length of 20 m. If exceeding this length of run, increase pipe sizes to 1/2” liguid line and 3/4” suction line.
Metal Cap
9) Remove the Metal Cap from the Ball Valve, and open the valve. See Fig. 8. Note: The unit is precharged with nitrogen gas.
Fig. 8
10) Weld the connections of liquid and suction lines with the Ball Valve body protected from overheating. Do not let the valve body exceed 150°C and the valve connections 700°C. 11) After tubing connections are complete, the connecting pipework should be leak-tested and evacuated.
3/8” OD
Ball Valve
12) The refrigeration connections are now complete. Proceed to sections 4 and 5 to continue with other service connection requirements before completing section 6, the start-up procedure.
Suction Line
5/8” OD Liquid Line
Fig. 9
4. ELECTRICAL CONNECTIONS WARNING
THIS APPLIANCE MUST BE EARTHED This icemaker requires an earth that meets the national and local electrical code requirements. To prevent possible severe electrical shock to individuals or extensive damage to equipment, install a proper earth wire to the icemaker. Remove the plug from the mains socket before any maintenance, repairs or cleaning is undertaken.
* This icemaker must have a separate power supply or receptacle of 220 - 240V. * The main control box fuse is rated at 12A and should only be replaced by a qualified service engineer.
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* Usually an electrical permit and services of a licensed electrician are required. * If the supply cord and the plug should need to be replaced, it should only be done by a qualified service engineer. For the U.K. and the Republic of Ireland only * The wires in the mains lead are coloured in accordance with the following code: Green & Yellow = Earth Blue = Neutral Brown = Live As the colours of the wire in the mains lead of this appliance may not correspond with the coloured markings identifying the terminals in your plug, proceed as follows: The wire which is coloured Green-and-Yellow must be connected to the terminal in the plug which is marked with the letter E or by the symbol or coloured Green or Green-andYellow. The wire which is coloured Blue must be connected to the terminal which is marked with the letter N or coloured Black. The wire which is coloured Brown must be connected to the terminal which is marked with the letter L or coloured Red. * Should the socket outlets in the installation site not be suitable for the plug supplied with your product, the plug must be removed (cut off if it is moulded on plug) and an appropriate plug fitted. If the non-rewirable plug has been cut from the power supply cord, it must be disposed of. There should be no attempt to reuse it. Inserting such a plug into a socket elsewhere presents a serious risk of electrical shock. * The non-rewirable plug must never be used without a fuse cover being fitted. The correct replacement for the detachable fuse cover is identifiable from the manufacturer’s reference number stamped on the plug. Supply of replacement fuse covers can be obtained from Hoshizaki Parts/Service Centres. Fuses should be rated at 13A and approved to BS 1362.
5. WATER SUPPLY AND DRAIN CONNECTIONS (For the U.K. only, the connections must be in accordance with current requirements of the Model Water Byelaws 1986 SI No. 1147) * Only potable water should be used for the icemaker.
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* Water supply pressure should be minimum 0.5 bar and maximum 8 bar. If the pressure exceeds 8 bar, use a proper pressure reducing valve. Do NOT throttle back the supply tap. * A plumbing permit and services of a licensed plumber may be required in some areas. * The icemaker drain is gravity flow, so ensure drain pipe has an adequate pitch or fall. * Water should drain into an open trap. 1) By means of a suitable spanner or wrench, tighten the 1/2-3/4 nipple (accessory) into the Rc1/2 fitting and the 3/4-3/4 nipple (accessory) into the R3/4 fitting on the rear of the icemaker as indicated. P.T.F.E. tape and/or a suitable sealing compound should be used to obtain a leak free joint. Note: Jointing compounds should be approved and suitable for potable water use. 2) Attach angled end of white flexible inlet hose (accessory) to free end of 1/2-3/4 nipple ensuring rubber sealing washer is correctly positioned. Hand tighten sufficiently to provide leak free joint. 3) Attach the other end of inlet hose to the water tap (Fig. 11), noting washer is correctly positioned before hand tightening as above. 4) Attach grey flexible outlet hose (accessory) to free end of 3/4-3/4 nipple as indicated, confirming fitment of rubber washer before finally hand tightening the joint. This pipe can be cut to length as necessary to suit position of main drain.
1/2-3/4 Nipple
Water Supply Inlet Rc1/2 Drain Outlet R3/4
Inlet Hose 3/4-3/4 Nipple
Outlet Hose
Water Supply Tap
Inlet Hose
Fig. 10
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Fig. 11
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IV. OPERATING INSTRUCTIONS WARNING 1. This icemaker is designed to produce and store edible ice. To keep the icemaker hygienic: * Wash your hands before removing ice. Use the Plastic Scoop provided (accessory). * The Storage Bin is for ice use only. Do not store anything else in the Bin. * Clean the Storage Bin before use (see “V. 1. PERIODICAL CLEANING”). * Keep the Scoop clean. Clean it by using a neutral cleaner and rinse thoroughly. * Close the Door after removing ice to prevent entrance of dirt, dust or insects into the Storage Bin. 2. The use of any electrical equipment involves the observance of some fundamental rules. In particular: * Instances of high humidity and moisture increase the risk of electrical short circuits and potential electrical shocks. If in doubt, disconnect the icemaker. * Do not pull the power cord in order to disconnect the icemaker from the feed network. * This appliance is not suitable for unsupervised use by young children or aged or infirm persons. 3. All parts are factory-adjusted. Improper adjustments may result in failure. 4. If the unit is turned off, wait for at least 3 minutes before restarting the icemaker to prevent damage to the Compressor.
1. START UP
Control Box
1) Make sure power and water supplies to the icemaker are off. 2) The condensing unit should be running and sufficiently charged with refrigerant.
FUSE(1A)
Fuse (1A) Flush Switch
ON
3) With the Front and Top Panels removed, check that the Flush Switch on the Control Box is in the “ICE” position.
POWER SWITCH OFF
Power Switch Lamp
SPOUT
Reset Switch (Gear Motor)
4) Open the water tap. 5) Connect the power supply and energise.
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6) The following should occur in sequence: a) Water Reservoir will fill. b) Gear Motor will start. c) Solenoid Valves will open. 7) After the icemaker has started, the evaporator pressure should be checked. The Evaporator Pressure Regulator should be adjusted to give a running evaporator pressure of 2.02 bar (FM-1000ALEE) or 3.36 bar (FM-1000ALFE). 8) Refit the Front and Top Panels in their correct position.
IMPORTANT 1. Check the conditions and quality of the ice production. Change ice size if necessary (see “VII. 2. FLAKE SIZE”). 2. Do not use ice produced in the trial run. It might be contaminated with foreign matter in the water circuit. Discard or flush down the drain. 3. Clean the Storage Bin before use (see “V. 1. PERIODICAL CLEANING”).
Note: This icemaker is designed to be connected with R22 (FM-1000ALE) or R404A (FM1000ALF) condensing unit. Connection with a condensing unit for any other type of refrigerant will require replacement of the Expansion Valve and adjustment of the EP Regulator. It is recommended to set the EP Regulator for the evaporating temperature of -22°C. Adjustment to the lower temperature may cause a serious trouble.
2. PREPARING THE ICEMAKER FOR LONG STORAGE WARNING When shutting off the icemaker for an extended time, drain out all water from the water line and remove ice from the Storage Bin. The Storage Bin should be cleaned and dried. Drain the icemaker to prevent damage to the water supply line at sub-freezing temperatures, using air or carbon dioxide. Shut off the icemaker until the proper ambient temperature is resumed.
1) Run the icemaker with the water supply tap closed. 2) Remove the Inlet Hose from the water tap, and drain the Hose. 3) Blow out the water inlet line by using air pressure. 4) Unplug the icemaker. U2CM4779901
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5) Remove the Front Panel. 6) Move the Flush Switch on the Control Box to the “FLUSH” position. 7) Plug in the icemaker, and then drain out all water from the water line. 8) Unplug the icemaker. 9) Replace the Front Panel in its correct position. 10) Replace the Inlet Hose in its correct position. 11) Remove all ice from the Storage Bin, and keep it clean and dry.
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V. MAINTENANCE WARNING 1. Before carrying out any cleaning or maintenance operations, unplug the icemaker from the electrical supply network. 2. This appliance must not be cleaned by use of a water jet.
1. PERIODICAL CLEANING [1] Machine and Bin Exterior Wipe the exterior at least once per week with a clean, soft cloth. Use a damp cloth containing a neutral cleaner to wipe off grease or dirt.
[2] Storage Bin Interior Cleaning/Sanitisation (as required) 1) Open the Storage Bin Door, and remove all ice. 2) Remove the Thumbscrews securing the Baffle. 3) Remove the Baffle from the Bin. 4) Wash the Bin Liner and Buffle with a neutral non-abrasive cleaner. Rinse thoroughly. 5) Mix 5 litres of water with 18 ml of 5.25% sodium hypochlorite solution in a suitable container. 6) Soak a clean sponge or cloth with the solution and wipe the Bin Liner surfaces and Baffle. 7) Refit the Baffle and Thumbscrews. Wipe the surface of the Bin Door and Thumbscrews with the solution. Close the Bin Door. 8) The remaining solution can be used to sanitise utensils. Note: Do not wipe dry or rinse after sanitising, but allow to air dry.
[3] Storage Bin Door Clean the Storage Bin Door at least once a week, using a neutral non-abrasive cleaner. Rinse thoroughly after cleaning and sanitise as required.
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2. CLEANING OF WATER SYSTEM WARNING 1. HOSHIZAKI recommends cleaning this unit at least once a year. More frequent cleaning, however, may be required in some existing water conditions. 2. To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners. 3. Always wear liquid-proof gloves for safe handling of the cleaning and sanitizing solutions. This will prevent irritation in case the solution contacts with skin.
Dilute the solutions with water as follows: Cleaning solution: A commercial cleaning agent is available at a refrigeration and airconditioning supply store. Use it according to the instructions on its label. Prepare approximately 3 lit. of cleaning solution. This is a minimum amount. Make more solution, if necessary. Sanitizing solution: 0.07 lit. of 5.25% sodium hypochlorite solution with 19 lit. of water.
IMPORTANT For safety and maximum effectiveness, use the solutions immediately after dilution.
Use the cleaning solution to remove lime deposits in the water system. 1) Unplug the icemaker. 2) Close the water supply tap. 3) Remove all ice from the Storage Bin. 4) Remove the Front Panel and the Top Panel. 5) Move the Flush Switch to the “FLUSH” position. 6) Plug in the icemaker, and drain out all water from the water line.
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7) Unplug the icemaker. 8) Remove the Control Water Valve by releasing the Fitting Nut. Do not lose the Packing. 9) Remove the Cover of the Reservoir. 10) Fill the Reservoir with the cleaning solution. 11) Replace the Cover of the Reservoir and the Control Water Valve in their correct position. Note: This unit is designed to start operating when the Reservoir is filled with water. 12) Move the 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, plug in the icemaker, 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 Switch to the “ICE” position. 18) Replace the Front Panel in its correct position. 19) Open the water supply tap, and supply water to the Reservoir. 20) Unplug the icemaker when the Gear Motor starts. 21) Drain out all water from the water line. See 4) through 7). Use 2.8 lit. of the sanitizing solution to sanitize the icemaker. 1) Close the water supply tap. 2) Remove the Control Water Valve by releasing the Fitting Nut. 3) Remove the Cover of the Reservoir. 4) Fill the Reservoir with the sanitizing solution. 5) Replace the Cover of the Reservoir and the Control Water Valve in their correct position.
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6) Move the Flush Switch to the “ICE” position. 7) Replace the Top Panel and the Front Panel in their correct position. 8) Allow the icemaker to set for about 10 minutes before the operation. Then, plug in the icemaker, and make ice using the solution until the icemaker stops icemaking. 9) Remove the Front Panel. 10) Move the Flush Switch to the “FLUSH” position to drain the 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 tap, and supply water to the Reservoir. 14) Unplug the icemaker 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. Use the sanitizing solution to sanitize removed parts. 1) Remove the Thumbscrew securing the Bin Control Switch on the Chute Assembly. 2) Remove the Band connecting the Spout with the Chute Assembly, and take out the Chute Assembly from the icemaker. 3) Remove one Gasket at the bottom of the Ice Chute and another at the Spout. 4) Rinse the three Ties and the Insulation of the Chute. 5) Remove the six Wing Nuts and two Baffles.
IMPORTANT When installing the Baffles, make sure that the bent surface (the one without the studs) faces the Activator so that the bent surface can guide the ice to the center of the Activator. 6) Remove the Bin Control Assembly by sliding it slightly toward the Spout and lifting it off.
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7) Disassemble the Bin Control Assembly by removing the two Snap Pins, Shaft and Activator. 8) Remove the three Thumbscrews and the Spout. 9) Remove the Rubber O-ring and Nylon Ring on 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 in their correct position. 13) Plug in and run the icemaker. 14) Unplug the icemaker after 30 minutes. 15) Pour warm water into the Storage Bin to melt the ice produced from the cleaning and sanitizing solutions. 16) Clean the Bin Liner, and rinse it thoroughly. 17) Plug in the icemaker, and start the automatic icemaking process.
IMPORTANT 1. After cleaning, do not use ice made from the sanitizing solution. Be careful not to leave any solution in the Storage Bin. 2. Follow carefully any instructions provided with the bottles of cleaning or sanitizing solution. 3. Never run the icemaker when the Reservoir is empty.
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VI. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT
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2. WIRING DIAGRAM
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3. DIFFERENCE BETWEEN -ALE AND -ALF The difference between -ALE (R22) models and -ALF (R404A) models is the Expansion Valve and Evaporating Pressure Regulator (EPR) setting. For proper superheat, a different Expansion Valve is provided for each refrigerant. The EPR is common for each model but is adjustable and different in the recommended setting. For -ALE models, the recommended setting is 2.27 bar and for -ALF models, 2.87 bar. If the icemaker operates at a pressure less than the above, each part in the Evaporator Assembly will get damaged or have a shorter life.
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4. TIMING CHART [a] PRINCIPLE OF OPERATION The icemaker starts water supply when the Power Switch is moved to “ON” position and the Flush Switch to the “ICE” position. When the water supply cycle is completed, the Gear Motor starts in 1 second in normal operation, the Solenoid Valve opens, and the refrigerant starts flowing into the Evaporator in 60 seconds. In normal operation, the icemaker stops when the Ice Storage Bin is filled up to activate the Bin Control Switch and also in the 20 minute flush cycle every 14 hours. In either case, the icemaker will automatically resume operation. Power ON
Flaot Switch
Control Water Valve Flush Control Valve Bin Control Switch Flush Timer Gear Motor Solenoid Valve
BIN FULL
FLUSH
20min
Upper Lower
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF 1sec 60sec
7sec
1sec
90sec
1sec
60sec
150sec
60sec
Fig. 10 [b] FLUSH SWITCH Moving the Flush Switch to the “ICE” position starts the normal icemaking process. Moving the Flush Switch to the “FLUSH” position brings the icemaker into the same operation as when the Flush Timer is switched to 1-2. The icemaker will not resume the icemaking process until the Flush Switch is manually moved to the “FLUSH” position.
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[c] PROTECTORS 1) Low Water Control The icemaker will stop when the water level in the Reservoir falls below the lower level of the Float Switch for suspension of water supply or low water pressure and does not reach the upper level within 90 seconds. When water starts to be supplied, the water level in the Reservoir will go up, and the icemaker will automatically resume the icemaking process.
2) Spout Switch If the Bin Control Switch does not work properly, the icemaking process will not end, and eventually the connection between the Ice Chute and the Spout will be broken. Then the Spout Switch will trip to stop the icemaking process. In this case, check the Bin Control Switch and the Ice Chute, and replace the Ice Chute if necessary. Power ON
Flaot Switch
Control Water Valve Flush Control Valve Bin Control Switch Flush Timer Gear Motor Solenoid Valve
Low Water
Spout Switch Off
Upper Lower
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF 1sec
90sec
1sec
60sec
150sec
60sec
Fig. 11
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VIII. REMOVAL AND REPLACEMENT OF COMPONENTS 1. SERVICE FOR REFRIGERANT LINES [a] REFRIGERANT RECOVERY The refrigerant must be recovered if required by an applicable law. The icemaker unit is provided with a Refrigerant Access Valve on the Evaporating Pressure Regulator. Recover the refrigerant from the Access Valve, and store it in a proper container. Do not discharge the refrigerant into the atmosphere.
[b] EVACUATION 1) Attach Charging Hoses, a Service Manifold and a Vacuum Pump to the system. 2) Turn on the Vacuum Pump. 3) Allow the Vacuum Pump to pull down to a 760 mmHg vacuum. Evacuating period depends on pump capacity. 4) Close the Low-side Valve on the Service Manifold. Note: Since the condensing unit connected to this icemaker has enough refrigerant, the system does not require recharging. 5) After restarting the icemaker, check the low side pressure, and disconnect the Hoses and Service Manihold. 6) Cap the Access Valve to prevent a possible leak.
2. BRAZING DANGER 1. Refrigerant R22 or R404A itself is not flammable, explosive and poisonous. However, when exposed to an open flame, R22 or R404A creates Phosgene gas, hazardous in large amounts. 2. Always recover the refrigerant and store it in a proper container, if required by an applicable law. Do not discharge the refrigerant into the atmosphere. 3. Do not use silver alloy or copper alloy containing Arsenic.
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4. In its liquid state, the refrigerant can cause frostbite because of the low temperature.
3. EXPANSION VALVE 1) Unplug the icemaker. 2) Remove the panels. 3) Recover the refrigerant and store it in a proper container, if required by an applicable law. 4) Remove the Expansion Valve Bulb at the Evaporator outlet. 5) Remove the Expansion Valve Cover, and disconnect the Expansion Valve using brazing equipment. 6) Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar.
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 120°C.
7) Check for leaks using nitrogen gas (10 bar) and soap bubbles. 8) Evacuate the system in the icemaker. 9) Attach the Bulb to the suction line. Be sure to secure the Bulb using a band and to insulate it. 10) Place the new set of Expansion Valve Covers in position. 11) Replace the panels in their correct position. 12) Plug in the icemaker.
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4. EVAPORATOR ASSEMBLY - See Fig. 12 1) Unplug the icemaker. 2) Remove the panels. 3) Move the Flush Switch to the “FLUSH” position to drain the water in the Evaporator. 4) Remove the Band connecting the Spout with the Chute Assembly. 5) Remove the three Thumbscrews, and take off the Spout from the Evaporator.
CORD HEATER 6) Unfasten the Protection Tape and Aluminum Foil Tape, and remove the Cord Heater. Be careful not to damage the Cord Heater.
CUTTER 7) Remove the Bolt and lift off the Cutter. 8) Remove the Rubber O-ring and the Nylon Ring at the top of the Evaporator.
EXTRUDING HEAD 9) Remove the four Socket Head Cap Screws, and lift off the Extruding Head. 10) Replace the Bearing inside the Extruding Head, if it is worn out or scratched. Note: Replacing the Bearing needs a fitting tool. If it is not available, replace the whole Extruding Head.
AUGER 11) Lift off the Auger. If the area in contact with the Bearing is worn out or the Blade scratched, replace the Auger.
EVAPORATOR Note: Skip the following steps 12) through 14) when the Evaporator does not need replacement.
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12) Recover the refrigerant and store it in a proper container, if required by an applicable law. 13) Remove the Bulb of the Expansion Valve. 14) Disconnect the brazing connections of the Expansion Valve and the Copper Tube - Low Side from the Evaporator, using brazing equipment.
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 120°C.
15) Remove the two Truss Head Machine Screws and the Strap securing the Evaporator. 16) Disconnect the three Hoses from the Evaporator. 17) Remove the four Socket Head Cap Screws securing the Evaporator with the Bearing Lower. 18) Lift off the Evaporator.
BEARING - LOWER AND MECHANICAL SEAL 19) 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. 20) Remove the O-ring on the Bearing - Lower. 21) Remove the six Bolts and the Bearing - Lower from the Gear Motor. Replace the Bearing inside the Bearing - Lower using a fitting tool, if it is worn out or scratched. Note: If a fitting tool is not available, replace the whole Bearing - Lower.
GEAR MOTOR 22) Remove the Coupling - Spline on the Gear Motor Shaft. 23) Remove the Barrier on the top of the Gear Motor. 24) Remove the Connector. 25) Remove the three Socket Head Cap Screws securing the Gear Motor.
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U2CM4779901
26) Assemble the removed parts in the reverse order of which they were removed.
WARNING Be careful not to scratch the surface of the O-ring, or it may cause water leaks. Handle the Mechanical Seal with care not to scratch nor to contaminate its contact surface.
27) When replacing the Evaporator; (a) Braze the new Evaporator with nitrogen gas flowing at the pressure of 0.2 - 0.3 bar. (b) Check for leaks using nitrogen gas (10 bar) and soap bubbles. (c) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required refrigerant charge. 28) Move the Flush Switch to the “ICE” position. 29) Replace the panels in their correct position. 30) Plug in the icemaker.
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Rubber O-ring Nylon Ring Bolt
Cutter
Extruding Head
Strap Socket Head Cap Screw
Evaporator
Socket Head Cap Screw
Auger
Mechanical Seal O-ring Bearing - Lower
Coupling -Spline
Gear Motor
Fig. 12 40
U2CM4779901
5. CONTROL WATER VALVE 1) Unplug the icemaker. 2) Close the water supply tap. 3) Remove the panels. 4) Disconnect the Terminals from the Control Water Valve. 5) Remove the Cover - Reservoir Inlet from the Control Water Valve. 6) 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. 7) Install the new Control Water Valve. 8) Assemble the removed parts in the reverse order of which they were removed. 9) Open the water supply tap. 10) Plug in the icemaker. 11) Check for water leaks. 12) Replace the panels in their correct position.
6. FLUSH WATER VALVE 1) Close the water supply tap. 2) Remove the panels. 3) Move the Flush Switch to the “FLUSH” position, and after 5 minutes move the Power Switch to the “OFF” position. 4) Remove the Clamp and disconnect the Hose from the Flush Water Valve. Note: Water may still remain inside the Evaporator. Be sure to drain the water into the Drain Pan. 5) Disconnect the Terminals from the Flush Water Valve. 6) Remove the Flush Water Valve from the Bracket. 7) Remove the Drain Pipe from the Flush Water Valve. U2CM4779901
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8) Connect the Drain Pipe to the new Flush Water Valve, and place the valve in position. 9) Connect the Hose to the Flush Water Valve, and secure it with the Clamp. 10) Pour water into the Reservoir, and check for water leaks on the Flush Water Valve. 11) Open the water supply tap. 12) Move the Power Switch to the “ON” position and then the Flush Switch to the “ICE” position. 13) Check for water leaks. 14) Move the Flush Switch to the “FLUSH” position, and make sure water is flushing. 15) Move the Flush Switch to the “ICE” position. 16) Replace the panels in their correct position.
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U2CM4779901
