Hoshizaki FM-481AGE-HC User manual

NO. F048-796
ISSUED: MAR. 1, 2010
REVISED: MAY 14, 2010
SERVICE MANUAL
HOSHIZAKI
MODULAR ICE MAKER
MODEL FM-481AGE-HC
FM-481AGE-HCN
FM-300AFE-HC
FM-300AFE-HCN

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WARNING
This machine contains flammable refrigerant. Do not attempt to break into the
refrigerant circuit unless qualified, competent and authorised to do so.
If any component of the refrigeration circuit requires removal or replacement, please
contact the manufacturer:
HOSHIZAKI EUROPE LIMITED
Telford 70 Stafford Park 7, Telford, Shropshire TF3 3BQ UK
Tel: [phone]
Fax: [phone]

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CONTENTS PAGE
I. SPECIFICATIONS-------------------------------------------------------------------------------------- 1
1. FEATURES ---------------------------------------------------------------------------------------------- 1
[a] LOW VOLTAGE------------------------------------------------------------------------------------ 1
[b] OVERLOAD PROTECTION--------------------------------------------------------------------- 1
[c] OVERLOAD ERROR------------------------------------------------------------------------------ 1
[d] USE RESET----------------------------------------------------------------------------------------- 1
[e] ERROR CODES AND RECORDS------------------------------------------------------------- 1
[f] OTHER INFORMATION -------------------------------------------------------------------------- 2
[g] CHANGE OF ICE TYPE-------------------------------------------------------------------------- 2
2. DIMENSIONS/CONNECTIONS -------------------------------------------------------------------- 3
[a] FM-481AGE-HC, FM-481AGE-HCN ---------------------------------------------------------- 3
[b] FM-300AFE-HC, FM-300AFE-HCN ----------------------------------------------------------- 4
3. SPECIFICATIONS ------------------------------------------------------------------------------------- 5
[a] FM-481AGE-HC------------------------------------------------------------------------------------ 5
[b] FM-481AGE-HCN---------------------------------------------------------------------------------- 6
[c] FM-300AFE-HC ------------------------------------------------------------------------------------ 7
[d] FM-300AFE-HCN ---------------------------------------------------------------------------------- 8
4. CONSTRUCTION-------------------------------------------------------------------------------------- 9
[a] FM-481AGE-HC, FM-481AGE-HCN ---------------------------------------------------------- 9
[b] FM-300AFE-HC, FM-300AFE-HCN ----------------------------------------------------------11
II. MAINTENANCE AND CLEANING INSTRUCTIONS-----------------------------------------12
1. EXTRUDING HEAD, HOUSING BEARING, AUGER BEARING--------------------------12
2. MECHANICAL SEAL---------------------------------------------------------------------------------12
3. GEAR MOTOR-----------------------------------------------------------------------------------------13
4. CONDENSER------------------------------------------------------------------------------------------13
5. AIR FILTER---------------------------------------------------------------------------------------------13
6. WATER VALVE----------------------------------------------------------------------------------------14
7. CLEANING OF WATER SYSTEM----------------------------------------------------------------15
8. PERIODICAL CLEANING---------------------------------------------------------------------------17
III. TECHNICAL INFORMATION----------------------------------------------------------------------18
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT-------------------------------------------18
[a] FM-481AGE-HC, FM-481AGE-HCN ---------------------------------------------------------18
[b] FM-300AFE-HC, FM-300AFE-HCN ----------------------------------------------------------19
2. WIRING DIAGRAM -----------------------------------------------------------------------------------20
[a] WIRING DIAGRAM-------------------------------------------------------------------------------20
[b] CONTROL BOX LAYOUT ----------------------------------------------------------------------22
3. ICEMAKING MECHANISM -------------------------------------------------------------------------24
[a] EVAPORATOR (CASING)----------------------------------------------------------------------24
[b] AUGER----------------------------------------------------------------------------------------------24
[c] EXTRUDING HEAD (BEARING)--------------------------------------------------------------25
[d] HOUSING-------------------------------------------------------------------------------------------25
[e] MECHANICAL SEAL-----------------------------------------------------------------------------25
[f] COUPLING (SPLINE JOINT)-------------------------------------------------------------------25
[g] GEAR MOTOR ------------------------------------------------------------------------------------25

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[h] BELT HEATER ------------------------------------------------------------------------------------25
[i] REMOVABLE FLANGE --------------------------------------------------------------------------25
[j] SOCKET HEAD CAP SCREW -----------------------------------------------------------------25
4. WATER CIRCUIT -------------------------------------------------------------------------------------26
[a] RESERVOIR (WATER TANK)-----------------------------------------------------------------26
[b] FLOAT SWITCH ----------------------------------------------------------------------------------26
[c] CONTROL WATER VALVE --------------------------------------------------------------------26
[d] FLUSH WATER VALVE-------------------------------------------------------------------------27
[e] DRAINING ICEMAKER IN SUBFREEZING CONDITIONS ----------------------------27
5. REFRIGERATION CIRCUIT------------------------------------------------------------------------28
[a] APPLICABLE PARTS----------------------------------------------------------------------------28
[b] SERVICE INSTRUCTIONS --------------------------------------------------------------------28
[c] REFRIGERANT -----------------------------------------------------------------------------------28
[d] COMPRESSOR -----------------------------------------------------------------------------------28
[e] EVAPORATOR CASING------------------------------------------------------------------------29
[f] CONDENSER --------------------------------------------------------------------------------------29
[g] CONDENSER COOLING FAN MOTOR ----------------------------------------------------29
[h] DRIER -----------------------------------------------------------------------------------------------29
[i] THERMOSTATIC EXPANSION VALVE -----------------------------------------------------29
6. ELECTRIC CIRCUIT ---------------------------------------------------------------------------------30
[a] BASIC OPERATION -----------------------------------------------------------------------------30
[b] TIMING CHART -----------------------------------------------------------------------------------30
[c] SEQUENCE ----------------------------------------------------------------------------------------33
[d] OPERATION BOARD----------------------------------------------------------------------------45
[e] CONTROLLER BOARD-------------------------------------------------------------------------45
[f] SURGE ABSORBER------------------------------------------------------------------------------46
[g] CAPACITOR - XY FILTER----------------------------------------------------------------------46
[h] BIN CONTROL SWITCH------------------------------------------------------------------------46
[i] CHUTE SWITCH-----------------------------------------------------------------------------------47
[j] DEICING HEATER (BELT HEATER) ---------------------------------------------------------47
7. OPERATION BOARD--------------------------------------------------------------------------------48
[a] USER OPERATION------------------------------------------------------------------------------48
[b] SERVICE OPERATION -------------------------------------------------------------------------48
8. PROTECTORS ----------------------------------------------------------------------------------------52
[a] INDICATION ---------------------------------------------------------------------------------------52
[b] PROTECTORS------------------------------------------------------------------------------------52
9. ERROR CODES---------------------------------------------------------------------------------------55
10. PERFORMANCE DATA ---------------------------------------------------------------------------57
[a] FM-481AGE-HC-----------------------------------------------------------------------------------57
[b] FM-481AGE-HCN---------------------------------------------------------------------------------58
[c] FM-300AFE-HC -----------------------------------------------------------------------------------59
[d] FM-300AFE-HCN ---------------------------------------------------------------------------------60
IV. SERVICE DIAGNOSIS -----------------------------------------------------------------------------61
1. NO ICE PRODUCTION------------------------------------------------------------------------------61
2. LOW ICE PRODUCTION----------------------------------------------------------------------------63
3. OTHERS-------------------------------------------------------------------------------------------------63
V. REMOVAL AND REPLACEMENT OF COMPONENTS-------------------------------------65

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I. SPECIFICATIONS
1. FEATURES
[a] LOW VOLTAGE
When the supply voltage is too low or surrounding high-current equipment starts up, the
voltage in the icemaker may drop temporarily. In this case, the Compressor will fail to start,
or the Gear Motor will lock during the icemaking operation. The locked Gear Motor may
apply the maximum torque to the icemaking mechanism and damage its parts. To avoid
this trouble, the icemaker will be shut down when the voltage drops. The icemaker will
restart automatically when the proper voltage is restored.
[b] OVERLOAD PROTECTION
The auger type icemaker employs the Gear Motor generating a large torque to scrape ice
forming inside the Evaporator. To produce nugget ice, the Extruding Head also requires a
large torque to compress ice. Some use conditions may overload the icemaking
mechanism. The icemaker will detect overload by reduction in Gear Motor rotation speed
and partly bypass the refrigerant flow in the refrigeration circuit. This will temporarily reduce
the ice production to avoid the overload condition.
[c] OVERLOAD ERROR
When the above protection fails to evade the overload condition and the Gear Motor has a
high current and a low rotation speed, the icemaker will shut down for protection. The
icemaking mechanism will have extensive damage, if this condition is repeated ten times. In
this case, the icemaker will display an error code to notify the user of the excessive load on
the icemaking mechanism and the need of its replacement.
[d] USER RESET
When a protector trips to shut down the icemaker, an error code will be displayed. If it is a
resettable error, the user can restart the icemaker by pressing the Reset Button accessible
from the Window Panel and continue the icemaking operation until a service person
arrives. Some errors are non-resettable or repetitive and require troubleshooting by
qualified personnel.
[e] ERROR CODES AND RECORDS
When the icemaker shuts down with an error, the Display Window will show an error code
“E_”. A maximum of eight most recent records are memorized and can be checked at the
time of service or inspection.

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[f] OTHER INFORMATION
Other information is also available from the Controller Board. See “III. 7. OPERATION
BOARD” for details.
[g] CHANGE OF ICE TYPE
With the older models, changes between flake ice and nugget ice were available by
replacing the Extruding Head and Cutter. With the new models, not only the Extruding
Head and Cutter but also the refrigeration circuit is different between the flake ice model
and nugget ice model. To ensure the proper capacity and prevent a trouble with excessive
ice production, do not replace the Extruding Head and Cutter to change the ice type.

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2. DIMENSIONS/CONNECTIONS
[a] FM-481AGE-HC, FM-481AGE-HCN

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[b] FM-300AFE-HC, FM-300AFE-HCN

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3. SPECIFICATIONS
[a] FM-481AGE-HC

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[b] FM-481AGE-HCN

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[c] FM-300AFE-HC

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[d] FM-300AFE-HCN

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4. CONSTRUCTION
Modular flaker models FM-481AGE-HC, FM-481AGE-HCN, FM-300AFE-HC and
FM-300AFE-HCN include Water Supply, Evaporator, Compressor, Condenser and Control
Assemblies. As the unit is not equipped with an Ice Storage Bin, this must be purchased
separately as optional extra.
[a] FM-481AGE-HC, FM-481AGE-HCN
Control Box
Compressor
Reservoir
Gear Motor
Evaporator
Flush Water Valve

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Drier
Ice Chute
Pressure Switch

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[b] FM-300AFE-HC, FM-300AFE-HCN
Control Box
Compressor
Reservoir
Drier
Ice Chute
Gear Motor Pressure Switch
Evaporator
Flush Water Valve

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II. MAINTENANCE AND CLEANING INSTRUCTIONS
IMPORTANT
1. This icemaker must be maintained individually, referring to the instruction manual
and labels provided with the icemaker.
2. To have the optimum performance of this icemaker, the following consumable
parts need periodical inspection, maintenance and replacement:
Extruding Head (Top Bearing)
Housing (Lower Bearing)
Mechanical Seal
These parts should be inspected at least once a year or every 10,000 hours of
operation. Their service life ultimately depends on water quality and environment,
therefore more frequent inspection and maintenance may be required.
1. EXTRUDING HEAD, HOUSING BEARING, AUGER BEARING
These parts should be replaced if a diametrical gap of more than 0.5 mm is found when at
least three spots are checked by changing the direction of the Auger on each Bearing.
It depends on the water quality and conditions, but normally the Bearings should be
checked for wear after a total of 8,000 - 10,000 hour operation from installation date.
Note: The clearance between the Auger blades and the Evaporator interior is 0.4 - 0.5 mm.
If the Bearings and rotating parts are worn out to create a larger clearance, the
Evaporator interior may be damaged. (The diameters differ by 0.8 - 1.0 mm.)
If the Auger surfaces against which the Bearings contact are no longer smooth or
show any burrs or abrasions during the above inspection, replace the auger.
2. MECHANICAL SEAL
The Mechanical Seal prevents water leaks from between the Auger and the Housing
Bearing and gradually wears out to reduce its watertightness. Check the amount of water
leakage from the Drain Pipe located at the side of the Gear Case to determine the
necessity of replacement.
Total operation time Water leakage
3,000 hours 0.1 mL/h
10,000 hours 0.5 mL/h
Note: The water leakage will exceed the above amount with scale/dirt build up or damage
on the mating surface. Replace the Mechanical Seal when the water leakage
exceeds 0.5 mL/h.

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3. GEAR MOTOR
After the following hours of operation, check the Gear Motor for excessive noise caused by
increased torque or deterioration of mechanical parts.
Bearing, Gear and other mechanical parts: 10,000 hours
Oil seal: 5 years
Note: When the output shaft oil seal is exposed to a large amount of water at one time,
water may enter the Gear Case. Always drain the water circuit before removing the
Auger for service.
4. CONDENSER
Check the Condenser once a year, and clean if required by using a brush or vacuum
cleaner. More frequent cleaning may be required depending on the location of the
icemaker.
5. AIR FILTER
Plastic mesh Air Filters remove dirt or dust from the air, and keep the Condenser from
getting clogged. If the Filters get clogged, the icemaker’s performance will be reduced.
Remove and clean the Air Filters at least twice per month:
1) Slide the Air Filter off the Louver.
2) Clean the Air Filter by using a vacuum cleaner. When severely clogged, use warm water
and a neutral cleaner to wash the Air Filter.
3) Rinse and dry the Air Filter thoroughly, and place it in position.

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6. WATER VALVE
1) Disconnect the power source.
2) Close the water supply tap.
3) Disconnect the Inlet Hose from the Water Valve.
4) Remove the Mesh Filter from the Water Valve.
5) Clean the Mesh using a brush.
6) Replace the Mesh and Inlet Hose in their correct positions.
7) Open the water supply tap.
8) Connect the power source.
9) Check for leaks.

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7. CLEANING OF WATER SYSTEM
WARNING
1. HOSHIZAKI recommends cleaning this unit at least twice a year. More frequent
cleaning, however, may be required in some existing water conditions.
2. Do not touch the Operation Switch with damp hands.
3. Always wear rubber gloves, eye protectors, apron, etc. for safe handling of the
cleaner and sanitiser.
4. Use the cleaners and sanitisers recommended by Hoshizaki. Contact your local
Hoshizaki office for further details. (The instructions below give an example of
those recommended cleaners and sanitisers.)
5. Never mix cleaning and sanitising solutions in an attempt to shorten cleaning
time.
6. Wipe off any splashed or spilt cleaner/sanitiser immediately.
7. Do not use any ammonia type cleaners on any part of the icemaker.
<STEP 1>
Dilute the solutions with water as follows:
Cleaning solution: “Nickel-Safe Ice Machine Cleaner” by The Rectorseal Corporation or
similar. Prepare approximately 3 L of solution as directed on the
container.
Sanitising solution: 30 mL of 5.25% sodium hypochlorite with 7.6 L of water or the
Hoshizaki recommended sanitiser as directed on the container.
IMPORTANT
For safety and maximum effectiveness, use the solutions immediately after dilution.
<STEP 2>
Use the cleaning solution to remove lime deposits in the water system.
1) Open the Plastic Access Flap on the Front Panel.
2) Press the Stop Button to activate the flush cycle (approx. 10 minutes).

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3) Remove all ice from the Storage Bin to avoid contamination by the cleaner.
4) Unplug the icemaker. Remove the Top and Front Panels.
5) Remove the Cover of the Reservoir. Remove any loose debris or scale.
6) Carefully fill the Reservoir with the solution to the overflow point. If necessary, use a
small brush to clean the inside of the Reservoir.
7) Refit the Reservoir Cover.
8) Check that the Operation Switch is in the “RUN” position.
9) Loose fit the Front and Top Panels.
10) Allow the icemaker to stand for about 10 minutes, then plug in the icemaker to make ice
with the solution.
11) With the water supply tap open, allow the machine to continue icemaking for a further
20 minutes. Open the Access Flap and press the Stop Button.
12) Allow time for the Gear Motor to stop and the water system to drain.
13) Unplug the icemaker.
14) Refit the Top and Front Panels. Plug in the icemaker.
15) Allow the icemaker to make ice for approximately 10 minutes.
16) Pour warm water into the Storage Bin to melt any ice down the drain.
Note: 1. If the machine has heavy deposits of scale, repeat the complete cleaning
procedure.
2. Do not increase the proportion of cleaning solution to shorten cleaning times, as
this may lock the Auger when completing item 10).
<STEP 3>
Note: Sanitising should always be completed after cleaning or alternately as an individual
procedure if conditions exist to make it necessary.
Use 2.8 litres of the sanitising solution to sanitise the icemaker.
17) Follow items 1) to 16) to complete sanitisation of the water system.