Hoshizaki FM-600ALKE-CO2-SB User manual

FM-600ALKE-CO2-SB
FM-600ALKE-CO2N-SB
FM-1200ALKE-CO2-SB
FM-1200ALKE-CO2N-SB
FM-1800ALKE-CO2-SB
FM-1800ALKE-CO2N-SB
F139-1088 (031020)
MODULAR ICE MAKER
SERVICE MANUAL

i
CONTENTS PAGE
I. SPECIFICATIONS -------------------------------------------------------------------------------------1
1. DIMENSIONS/SPECIFICATIONS--------------------------------------------------------------1
[a] FM-600ALKE-CO2-SB------------------------------------------------------------------------1
[b] FM-600ALKE-CO2N-SB ---------------------------------------------------------------------2
[c] FM-1200ALKE-CO2-SB ----------------------------------------------------------------------3
[d] FM-1200ALKE-CO2N-SB -------------------------------------------------------------------4
[e] FM-1800ALKE-CO2-SB ----------------------------------------------------------------------5
[f] FM-1800ALKE-CO2N-SB--------------------------------------------------------------------6
2. CONSTRUCTION ----------------------------------------------------------------------------------7
[a] FM-600ALKE-CO2(N)-SB -------------------------------------------------------------------7
[b] FM-1200ALKE-CO2(N)-SB------------------------------------------------------------------8
[c] FM-1800ALKE-CO2(N)-SB------------------------------------------------------------------9
[d] BIN CONTROL SWITCH AND SPOUT------------------------------------------------- 10
II. MAINTENANCE AND CLEANING INSTRUCTIONS--------------------------------------- 11
1. PERIODIC PARTS REPLACEMENT-------------------------------------------------------- 11
2. EXTRUDING HEAD (UPPER BEARING), HOUSING (LOWER BEARING) ------ 12
3. MECHANICAL SEAL ---------------------------------------------------------------------------- 12
4. GEAR MOTOR------------------------------------------------------------------------------------ 13
5. CONTROL WATER VALVE -------------------------------------------------------------------- 13
6. CLEANING OF WATER SYSTEM ----------------------------------------------------------- 14
III. TECHNICAL INFORMATION -------------------------------------------------------------------- 17
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT--------------------------------------- 17
[a] FM-600ALKE-CO2(N)-SB ----------------------------------------------------------------- 17
[b] FM-1200ALKE-CO2(N)-SB---------------------------------------------------------------- 18
[c] FM-1800ALKE-CO2(N)-SB---------------------------------------------------------------- 19
2. WIRING DIAGRAM ------------------------------------------------------------------------------ 20
[a] WIRING DIAGRAM-------------------------------------------------------------------------- 20
[b] CONTROL BOX LAYOUT ----------------------------------------------------------------- 23
3. ICEMAKING MECHANISM -------------------------------------------------------------------- 26
[a] EVAPORATOR (CASING) ----------------------------------------------------------------- 27
[b] AUGER ----------------------------------------------------------------------------------------- 27
[c] EXTRUDING HEAD (BEARING)--------------------------------------------------------- 27
[d] HOUSING-------------------------------------------------------------------------------------- 27
[e] MECHANICAL SEAL------------------------------------------------------------------------ 27
[f] COUPLING (SPLINE JOINT) ------------------------------------------------------------- 27
[g] GEAR MOTOR ------------------------------------------------------------------------------- 27
[h] BELT HEATER (provided on nugget type)--------------------------------------------- 28
[i] REMOVABLE FLANGE -------------------------------------------------------------------- 28
[j] SEALING BOLT ------------------------------------------------------------------------------ 28
[k] BIN CONTROL SWITCH ------------------------------------------------------------------ 29
[l] SPOUT, SPOUT COVER ----------------------------------------------------------------- 30
4. ELECTRIC CIRCUIT----------------------------------------------------------------------------- 31
[a] BASIC OPERATION ------------------------------------------------------------------------ 31
[b] TIMING CHART ------------------------------------------------------------------------------ 32

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5. OPERATION BOARD --------------------------------------------------------------------------- 33
[a] OPERATION BUTTONS ------------------------------------------------------------------- 33
[b] SETTING MODEL NUMBER-------------------------------------------------------------- 33
[c] DISPLAYING COMPRESSOR OPERATING HOURS, CYCLE TIME,
MODEL NUMBER AND SOFTWARE VERSION ------------------------------------ 34
[d] DISPLAYING ERROR LOG --------------------------------------------------------------- 36
[e] RESETTING ERROR LOG---------------------------------------------------------------- 37
[f] RESETTING COMPRESSOR OPERATING HOURS ------------------------------ 37
[g] REDUCING COMPRESSOR STARTING TIME-------------------------------------- 38
6. PROTECTORS------------------------------------------------------------------------------------ 38
[a] INDICATION----------------------------------------------------------------------------------- 38
7. ERROR CODES ---------------------------------------------------------------------------------- 39
8. PERFORMANCE DATA------------------------------------------------------------------------- 41
[a] FM-600ALKE-CO2-SB---------------------------------------------------------------------- 41
[b] FM-600ALKE-CO2N-SB ------------------------------------------------------------------- 41
[c] FM-1200ALKE-CO2-SB -------------------------------------------------------------------- 42
[d] FM-1200ALKE-CO2N-SB------------------------------------------------------------------ 42
[e] FM-1800ALKE-CO2-SB -------------------------------------------------------------------- 43
[f] FM-1800ALKE-CO2N-SB------------------------------------------------------------------ 43
IV. SERVICE DIAGNOSIS---------------------------------------------------------------------------- 44
1. NO ICE PRODUCTION ------------------------------------------------------------------------- 44
2. LOW ICE PRODUCTION----------------------------------------------------------------------- 46
3. OTHERS-------------------------------------------------------------------------------------------- 47
V. REMOVAL AND REPLACEMENT OF COMPONENTS ----------------------------------- 48
1. SERVICE FOR REFRIGERANT LINES ---------------------------------------------------- 48
[a] SERVICE INFORMATION ----------------------------------------------------------------- 48
[b] EVACUATION AND RECHARGE -------------------------------------------------------- 49
2. BRAZING ------------------------------------------------------------------------------------------- 49
3. ELECTRONIC EXPANSION VALVE (E.E.V.)---------------------------------------------- 49
4. EVAPORATOR ASSEMBLY ------------------------------------------------------------------- 50
5. CONTROL WATER VALVE -------------------------------------------------------------------- 53
6. FLUSH WATER VALVE ------------------------------------------------------------------------- 53
7. CONTROLLER BOARD ------------------------------------------------------------------------ 54
[a] MODIFICATION ------------------------------------------------------------------------------ 54
[b] REPLACEMENT ----------------------------------------------------------------------------- 54

1
I. SPECIFICATIONS
1. DIMENSIONS/SPECIFICATIONS
[a] FM-600ALKE-CO2-SB

2
[b] FM-600ALKE-CO2N-SB

3
[c] FM-1200ALKE-CO2-SB

4
[d] FM-1200ALKE-CO2N-SB

5
[e] FM-1800ALKE-CO2-SB

6
[f] FM-1800ALKE-CO2N-SB

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2. CONSTRUCTION
[a] FM-600ALKE-CO2(N)-SB
Control Water Valve
Bin Control Switch
Control Box
EPR
Gear Motor
Flush Water Valve Evaporator Reservoir
Spout
Solenoid Valve
Safety Valve

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[b] FM-1200ALKE-CO2(N)-SB
Control Water Valve
Bin Control
Switch
Control Box
EPR
Gear Motor
Flush Water
Valve
Evaporator
Spout
Solenoid
Valve
Safety
Valve
Reservoir
Evaporator

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[c] FM-1800ALKE-CO2(N)-SB
Spout
Reservoir
Evaporator
Gear
Motor
Bin Control
Switch
Control Water Valve
Flush Water
Valve
Safety
Valve
Solenoid
Valve
Evaporator
EPR

10
[d] BIN CONTROL SWITCH AND SPOUT
Actuator
Reed Switch
(Bin Control)
Reed Switch
(Spout Switch)
Spout Cover
Spring Spout
Chute

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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 achieve optimum icemaker performance, the following parts need periodic
inspection and maintenance:
Extruding head (upper bearing)
Housing (lower bearing)
Mechanical seal
These parts should be inspected after two years from installation or 10,000 hours
of operation, whichever comes rst, and once a year thereafter. Their service life,
however, depends on water quality and environment. More frequent inspection
and maintenance are recommended in bad or severe water conditions.
1. PERIODIC PARTS REPLACEMENT
The extruding head (upper bearing) and mechanical seal must be replaced after four years
from installation or 20,000 hours of operation, whichever comes rst.
Operation Panel
Ice Button Display Stop Button
Maintenance Button Operation Switch
When the total operating time reaches 20,000 hours, the display ashes “PC”. Then, after
500 hours, the unit shuts down to ensure safety. The operation can be resumed by turning
o󰀨 the operation switch and turning it back on. But the unit shuts down again after 500
hours and cannot be restarted.
This information is provided on the label attached to the front panel and in the instruction
manual. But instruct the user to contact a Hoshizaki service agent for replacement as soon
as the display starts ashing “PC”.

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After replacing the extruding head and mechanical seal:
1) Reset the compressor operating hours in accordance with “III. 5. [f] RESETTING
COMPRESSOR OPERATING HOURS”. The “PC” indication on the display goes o󰀨.
2) Record the date of replacement on the label attached to the front panel.
Operating Hours “PC” Indication
0 to 20,000 hours None
20,000 to 20,500 hours “PC” > “ICE” > “PC” > “ICE” > “PC” > “ICE” > “PC” > ......
* Flashes every second.
20,500 to 21,000 hours “PC” > “PC” > “ICE” > “PC” > “PC” > “ICE” > “PC” > ......
* Flashes every second.
Replace the parts as soon as possible.
2. EXTRUDING HEAD (UPPER BEARING), HOUSING (LOWER 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 di󰀨er 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. The
sealing bolt must be tightened equally to torque of 784N·cm±10%.
3. 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
Attach the mechanical seal with its oating sheet facing the housing. After replacement,
there should be no water leakage from the mating surface.
0.5 mm Round Stock
or Pin Gauge
Auger
Extruding
Head
For reference only
(May di󰀨er from actual design)

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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.
4. 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.
5. CONTROL WATER VALVE
1) Disconnect the power source.
2) Close the water supply tap.
3) Disconnect the inlet hose from the water valve.
4) Clean the lter packing using a brush.
5) Replace the lter packing and inlet hose in their correct positions.
6) Open the water supply tap.
7) Connect the power source.
8) Check for leaks.

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6. 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 o󰀩ce 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 o󰀨 any splashed or spilt cleaner/sanitiser immediately.
7. Do not use any ammonia type cleaners on any part of the icemaker.
Control Water Valve
Filter Packing
Inlet Hose

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CAUTION
Do not use ice produced with cleaning and sanitizing solutions. Be sure none
remains in the storage bin on completion of cleaning.
<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 e󰀨ectiveness, 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 ap on the front panel.
2) Press the stop button to activate the ush cycle (approx. 10 minutes).
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) Ret the reservoir cover.
8) Check that the operation switch is in the “ON” position.
9) Ret 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 ap and press the stop button.

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12) Allow time for the gear motor to stop and the water system to drain.
13) Allow the icemaker to make ice for approximately 10 minutes.
14) 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.
15) Follow items 1) to 14) to complete sanitisation of the water system.

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III. TECHNICAL INFORMATION
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT
[a] FM-600ALKE-CO2(N)-SB
Reservoir
Electronic
Expansion
Valve
Flush
Water
Valve
Safety
Valve Evaporator
Float
Switch
Control
Water
Valve
Solenoid
Valve
EPR