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NO. E2TA-684
ISSUED: SEP. 23, 2005
REVISED: JUN. 26, 2007
HOSHIZAKI
THIN GLASS ICE MAKER
SERVICE MANUAL
MODEL TM-500AAE
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CONTENTS PAGE
I. SPECIFICATIONS------------------------------------------------------------------------------------- 1
1. FEATURES ---------------------------------------------------------------------------------------- 1
[a] FLOOR MOUNTING AND FIXED MOUNTING ---------------------------------------- 1
[b] BIN CONTROL ADJUSTMENT (Fixed Mounting Only) ------------------------------ 1
[c] ICE PRODUCTION CONTROL (Fan Control)------------------------------------------ 1
[d] OVERLOAD PROTECTION --------------------------------------------------------------- 1
[e] USER RESET--------------------------------------------------------------------------------- 1
[f] ERROR CODES AND RECORDS------------------------------------------------------- 1
[g] OTHER INFORMATION--------------------------------------------------------------------- 2
[h] CHANGE OF ICE TYPE -------------------------------------------------------------------- 2
2. DIMENSIONS/CONNECTIONS --------------------------------------------------------------- 3
3. SPECIFICATIONS ------------------------------------------------------------------------------- 4
4. CONSTRUCTION--------------------------------------------------------------------------------- 5
II. MAINTENANCE AND CLEANING INSTRUCTIONS ------------------------------------------ 6
1. TIMING BELT -------------------------------------------------------------------------------------- 6
2. CONDENSER------------------------------------------------------------------------------------- 6
3. AIR FILTER ---------------------------------------------------------------------------------------- 6
4. GREASE UP (BEARING)----------------------------------------------------------------------- 6
5. PERIODICAL CLEANING ---------------------------------------------------------------------- 7
III. TECHNICAL INFORMATION----------------------------------------------------------------------- 8
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT ---------------------------------------- 8
2. WIRING DIAGRAM ------------------------------------------------------------------------------- 9
[a] WIRING DIAGRAM --------------------------------------------------------------------------- 9
[b] CONTROL BOX LAYOUT -----------------------------------------------------------------10
3. ICEMAKING MECHANISM--------------------------------------------------------------------11
[a] EVAPORATOR (DRUM) ------------------------------------------------------------------11
[b] CUTTER---------------------------------------------------------------------------------------11
[c] BEARING--------------------------------------------------------------------------------------11
[d] MECHANICAL SEAL ----------------------------------------------------------------------11
[e] HEATER (CUTTER) ------------------------------------------------------------------------12
[f] HEATER (TANK) ----------------------------------------------------------------------------12
[g] GEAR MOTOR-------------------------------------------------------------------------------12
4. WATER CIRCUIT --------------------------------------------------------------------------------12
[a] FLOAT SWITCH-----------------------------------------------------------------------------12
[b] CONTROL WATER VALVE --------------------------------------------------------------12
[c] FLUSH WATER VALVE-------------------------------------------------------------------13
[d] DRAINING ICEMAKER IN SUBFREEZING CONDITIONS-------------------------13
5. REFRIGERATION CIRCUIT -------------------------------------------------------------------14
[a] APPLICABLE PARTS ---------------------------------------------------------------------14
[b] SERVICE INSTRUCTIONS ---------------------------------------------------------------14
[c] REFRIGERANT CONTROL (Compressor Cooling) ---------------------------------14
[d] REFRIGERANT CONTROL (Ice Production Control) -------------------------------14
[e] REFRIGERANT ------------------------------------------------------------------------------14
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[f] COMPRESSOR -----------------------------------------------------------------------------15
[g] EVAPORATOR (DRUM) ------------------------------------------------------------------15
[h] CONDENSER--------------------------------------------------------------------------------15
[i] CONDENSER COOLING FAN MOTOR -----------------------------------------------16
[j] DRIER ------------------------------------------------------------------------------------------16
[k] SOLENOID VALVE-------------------------------------------------------------------------16
[l] THERMOSTATIC EXPANSION VALVE -----------------------------------------------16
[m] ACCESS VALVE --------------------------------------------------------------------------16
[n] RECEIVER TANK ---------------------------------------------------------------------------16
6. ELECTRIC CIRCUIT ----------------------------------------------------------------------------17
[a] BASIC OPERATION------------------------------------------------------------------------17
[b] TIMING CHART (Floor Mounting) --------------------------------------------------------18
[c] TIMING CHART (Fixed Mounting) --------------------------------------------------------19
[d] SEQUENCE----------------------------------------------------------------------------------20
[e] OPERATION BOARD ----------------------------------------------------------------------33
[f] CONTROLLER BOARD -------------------------------------------------------------------33
[g] CAPACITOR - XY FILTER ----------------------------------------------------------------33
[h] BIN CONTROL SWITCH (Fixed Mounting Only) --------------------------------------34
[i] SPOUT SWITCH (Proximity Switch) ----------------------------------------------------34
[j] CRANKCASE HEATER -------------------------------------------------------------------34
7. OPERATION BOARD --------------------------------------------------------------------------35
[a] USER OPERATION ------------------------------------------------------------------------35
[b] SERVICE OPERATION--------------------------------------------------------------------36
8. PROTECTORS ----------------------------------------------------------------------------------37
[a] INDICATION ----------------------------------------------------------------------------------37
[b] PROTECTORS ------------------------------------------------------------------------------37
9. ERROR CODES---------------------------------------------------------------------------------39
10. PERFORMANCE DATA ----------------------------------------------------------------------41
[a] TM-500AAE (Thick Ice) --------------------------------------------------------------------41
[b] TM-500AAE (Thin Ice)----------------------------------------------------------------------42
IV. SERVICE DIAGNOSIS ----------------------------------------------------------------------------43
1. NO ICE PRODUCTION-------------------------------------------------------------------------43
2. LOW ICE PRODUCTION ----------------------------------------------------------------------44
3. OTHERS-------------------------------------------------------------------------------------------45
V. REMOVAL AND REPLACEMENT OF COMPONENTS -----------------------------------46
1. SERVICE FOR REFRIGERANT LINES ----------------------------------------------------46
[a] SERVICE INFORMATION -----------------------------------------------------------------46
[b] REFRIGERANT RECOVERY ------------------------------------------------------------47
[c] EVACUATION AND RECHARGE-------------------------------------------------------47
2. BRAZING ------------------------------------------------------------------------------------------48
3. COMPRESSOR ---------------------------------------------------------------------------------49
4. DRIER ----------------------------------------------------------------------------------------------50
5. EXPANSION VALVE---------------------------------------------------------------------------51
6. EVAPORATOR ASSEMBLY -----------------------------------------------------------------52
7. CONTROL WATER VALVE ------------------------------------------------------------------58
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8. FLUSH WATER VALVE -----------------------------------------------------------------------59
9. CONTROLLER BOARD -----------------------------------------------------------------------60
10. LINE VALVE--------------------------------------------------------------------------------------60
1
I. SPECIFICATIONS
1. FEATURES
[a] FLOOR MOUNTING OR FIXED MOUNTING
The floor mounting and fixed mounting options are available. Use the rotary Select Switch
provided on top of the Operation Panel to choose between the two options. If the fixed mounting
option is selected, the Bin Control Switch in the Control Box will become functional.
[b] BIN CONTROL ADJUSTMENT (Fixed Mounting Only)
The sensitivity of the Bin Control Switch in the Control Box is factory-adjusted for the standard
Storage Bin B-500. If requested by the customer, it is adjustable by turning the Adjust Screw on
the Bin Control Switch. See "4. BIN CONTROL ADJUSTMENT" in the installation manual for
further details.
[c] ICE PRODUCTION CONTROL (Fan Control)
The ice production will increase at low ambient or water temperature. As a result, the Gear
Motor will have a higher torque to harvest ice, and the icemaking mechanism will be overloaded.
To prevent this condition, the icemaker controls the Fan Motor rotation speed to keep the
discharge pressure in the refrigeration circuit within a proper range.
[d] OVERLOAD PROTECTION
Despite the above-mentioned ice production control, some use conditions (water quality etc.)
or variable part tolerances may overload the icemaking mechanism. A photomicrosensor will
detect overload by reduction in Drum rotation speed and shut down the icemaker. This can
avoid a costly breakdown of the icemaking mechanism or the like.
[e] 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.
[f] 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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[g] OTHER INFORMATION
Other information is also available from the Controller Board. See "III. 7. OPERATION BOARD"
for details.
[h] CHANGE OF ICE TYPE
The ice type is changeable by replacing the Pulleys provided on the Gear Motor and Gear Head
driving the Evaporator (Drum). The icemaker is factory-adjusted in the "Thick Ice" mode, but
can be changed to the "Thin Ice" mode by replacing the Pulleys.
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2. DIMENSIONS/CONNECTIONS
4
3. SPECIFICATIONS
AC SUPPLY VOLTAGE
AMPERAGE
STARTING AMPERAGE
ELECTRIC CONSUMPTION
POWER FACTOR
POWER SUPPLY CAPACITY
1 PHASE 230V 50Hz
10.3A (Ambient temp. 32°C, Water temp. 21°C)
75.9A
2035W (Ambient temp. 32°C, Water temp. 21°C)
85.6%
Min 4.8kVA (20.9A)
ICE PRODUCTION PER 24h Thick Ice Thin Ice
Approx. 520 kg 630 kg (Ambient temp. 10°C, Water temp. 10°C)
Approx. 460 kg 550 kg (Ambient temp. 21°C, Water temp. 15°C)
Approx. 380 kg 460 kg (Ambient temp. 32°C, Water temp. 21°C)
WATER CONSUMPTION PER 24h Thick Ice Thin Ice
Approx. 0.53 m
3
0.64 m
3
(Ambient temp. 10°C, Water temp. 10°C)
Approx. 0.47 m
3
0.56 m
3
(Ambient temp. 21°C, Water temp. 15°C)
Approx. 0.39 m
3
0.47 m
3
(Ambient temp. 32°C, Water temp. 21°C)
SHAPE OF ICE
MAX. STORAGE CAPACITY
Scale Ice
Not Applicable
DIMENSIONS (DRAWING No.)
EXTERIOR
CONNECTION - ELECTRIC
- WATER SUPPLY
- DRAIN
761(W) x 524(D) x 800(H) (362948)
Stainless Steel, Galvanized Steel (Rear)
Y-type Con.
Inlet G 3/4” (Connected at rear side)
Outlet R 3/4” (Connected at rear side)
ICE MAKING SYSTEM
HARVESTING SYSTEM
Drum type
Continuous ice making system
COMPRESSOR
CONDENSER
HEAT REJECTION
EVAPORATOR
REFRIGERANT CONTROL
REFRIGERANT CHARGE
Hermetic Compressor Model CS20K6E-PFZ
Fin and Tube type, Air-cooled (Fan Motor output 30W)
2980W (Ambient temp. 32°C, Water temp. 21°C)
Aluminum Horizontal Drum
Thermostatic Expansion Valve
R404A 1900g
BIN CONTROL SYSTEM
ICE MAKING WATER CONTROL
Infrared ray Sensor (Time Delay Controlled)
Float Switch and Water Valve
ELECTRICAL PROTECTION
REFRIGERATION CIRCUIT
PROTECTION
GEAR MOTOR PROTECTION
LOW WATER PROTECTION
BIN CONTROL PROTECTION
INTERLOCK
Class I Appliance, 3.15A Fuse
Compressor Internal Motor Protector, Internal Pressure Relief Valve,
Pressure Switch (Auto-reset)
Thermal Protector (Auto-reset), Motor Rotation Protection
Float Switch and Microprocessor
Micro Switch (Manual-reset)
Shutdown by Microprocessor (Manual-reset)
WEIGHT
PACKAGE
Net weight 152 kg / Gross weight 166 kg
Carton 865mm(W) x 700mm(D) x 972mm(H)
ACCESSORIES Installation Kit
OPTION Chute, Top Kit
OPERATION CONDITIONS
AMBIENT TEMP.
WATER SUPPLY TEMP.
WATER SUPPLY PRESSURE
VOLTAGE RANGE
5-40°C
5-35°C
0.5-8 bar (0.05-0.8MPa)
Rated Voltage ± 10%
We reserve the right to make changes in specifications and design without prior notice.
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4. CONSTRUCTION
Control Water Valve
Float Switch
Expansion Valve
Gear Motor
Receiver Tank
Drier
Fan Motor
Line Valve
Control Box - Main
Control Box - Operation
Pressure Switch
Icemaking Unit
Flush Water Valve
Compressor
To
p
View
Front View
Left Side View Ri
g
ht Side View
6
II. MAINTENANCE AND CLEANING INSTRUCTIONS
IMPORTANT
This icemaker must be maintained individually, referring to the instruction manual
and labels provided with the icemaker.
1. TIMING BELT
The Timing Belt transmits power from the Gear Motor to the Gear Head. It may wear or deteriorate
and break after a total of 15,000 hours of Gear Motor operation.
2. 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.
3. AIR FILTER
A plastic mesh Air Filter removes dirt or dust from the air, and keeps the Condenser from getting
clogged. As the Filter gets clogged, the icemaker’s performance will be reduced. Remove and
clean the Air Filter at least twice per month:
1) Push down the Lock and take off the Louver.
Note: Do not put your hand inside the machine compartment.
2) Remove the Air Filter by pushing it down.
3) Clean the Air Filter by using a vacuum cleaner. When severely
clogged, use warm water and a neutral cleaner to wash the Air
Filter.
4) Rinse and dry the Air Filter thoroughly, and place it in position.
4. GREASE UP (BEARING)
The Bearing supporting the Drum rotation requires periodic greasing. Use Dow Corning G-
4500 to grease up the Bearing once a year. See step 32) in "V. 7. EVAPORATOR ASSEMBLY"
for the replacement procedure.
Exterior Panel
Lock
Air Filter
Louver
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5. 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) [fixed mounting only]
1) Open the Storage Bin Door, and remove all ice.
2) Wash the Bin Liner, Ice Deflector and Door inner surface with a neutral non-abrasive cleaner.
Rinse thoroughly with a clean cloth and fresh water.
3) Mix 5 litres of water with 18 mL of 5.25% sodium hypochlorite solution in a suitable container
or the recommended Hoshizaki sanitiser as directed.
4) Soak a clean sponge or cloth with the solution and wipe all the surfaces of the Bin Liner, Ice
Deflector and Door inner surface.
5) Rinse thoroughly with fresh water and a clean cloth to wipe off the solution. Close the Bin
Door.
Note: Some solutions may cause damage to the Bin liner surfaces or corrosion on the metal
parts. Always rinse the sanitiser unless directed otherwise by Hoshizaki guidelines.
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III. TECHNICAL INFORMATION
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT
Pressure Switch
Low Side
Cut-out 0.03 ± 0.02 MPa
Cut-in 0.1 ± 0.02 MPa
High Side
Cut-out 3.2 ± 0.02 MPa
Cut-in 2.55 ± 0.02 MPa
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2. WIRING DIAGRAM
[a] WIRING DIAGRAM
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[b] CONTROL BOX LAYOUT
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3. ICEMAKING MECHANISM
[a] EVAPORATOR (DRUM)
The Evaporator consists of an aluminum alloy cylinder with an icemaking surface on its exterior,
a press-fit plastic part with a refrigerant path, and a shaft for refrigerant supply and rotation. The
Evaporator penetrates the side of the Tank, and the Cutter scrapes off ice forming on the
Evaporator surface.
[b] CUTTER
The stainless steel Cutter is fixed on the Tank so that it can be repositioned against the Evaporator.
[c] BEARING
The Bearing is installed on one side of the Tank to support the Evaporator (Drum) Shaft. The
Gear Head provides the same function on the other side of the Tank where the Gear Motor is
located to drive the Drum.
[d] MECHANICAL SEAL
The Mechanical Seal prevents refrigerant leaks from the rotating Drum. The rotary ring attached
to the Shaft and the stationary ring fixed on the Housing form a carbon ring shaft sealing system.
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[e] HEATER (CUTTER)
The Heater provided on the backside of the Cutter prevents ice jamming on the Cutter resulting
in a clogged Spout and ice forming on the back of the Cutter at a low temperature. The thermal
sensor attached on the water inlet controls to energize the Heater.
[f] HEATER (TANK)
The Heater provided inside the Tank prevents the Float Switch from freezing. As with the Heater
for the Cutter, the thermal sensor attached on the water inlet controls to energize the Heater.
[g] GEAR MOTOR
The Gear Motor consists of a 1 phase 230V drive motor integrated with a decelerator and
provided with a built-in auto-reset Thermal Protector. When the Thermal Protector trips, the
Controller Board will stop the Gear Motor. The Protector can be reset by the Reset Button on
the Operation Board. The Thermal Protector trips when the Gear Motor mechanism is overloaded
or when excessively high or low voltage is applied on the Gear Motor. The electrical capacity
must be increased if a large current flows through the surrounding equipment.
4. WATER CIRCUIT
[a] FLOAT SWITCH
The Tank holding the Evaporator is provided with a plastic Float Switch to detect the water level.
The floats move up and down along with the water level and send ON/OFF signals to open/close
the Water Valve in order to maintain the proper water level.
If the proper water level cannot be resumed within about 20 minutes after the Float Switch sends
an OFF signal, the icemaker will detect a low water condition and shut down. The icemaker will
automatically restart icemaking operation when the proper water level is resumed within 80
minutes.
If the Float Switch trips at the upper float level for 10 minutes after the Tank fills up, the icemaker
will display “E1” for no ice production error and shut down.
If the Float Switch trips at both upper (fill) and lower (empty) float levels, the icemaker will display
“E2” for a switch contact error and shut down.
See “9. ERROR CODES” for details.
[b] CONTROL WATER VALVE
The Control Water Valve located above the Tank will open to supply water to the Tank when the
coil is energized. Despite the water pressure varying from 0.3 bar to 8 bar at the water supply
inlet, the built-in flow controller maintains almost the same water flow (100V AC).
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[c] FLUSH WATER VALVE
The Flush Water Valve is energized to open and flush out the Tank (100V AC) after the icemaker
shuts down and every 12 hours when the Storage Bin is used.
[d] DRAINING ICEMAKER IN SUBFREEZING CONDITIONS
In winter, the water circuit must be completely drained out or otherwise protected to prevent
freeze-up and damage before shutting down the icemaker at night.
1) Close the Water Supply Line Shut-off Valve to stop water supply.
2) Open the Air Shut-off Valve.
3) Press the Stop Button, and drain the Float Tank and Evaporator.
4) Turn off the icemaker.
Before restarting the icemaker:
1. Close the Air Shut-off Valve.
2. Open the Water Supply Line Shut-off Valve.
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5. REFRIGERATION CIRCUIT
[a] APPLICABLE PARTS
Refrigerant (R404A)
Compressor
Evaporator Tank
Air-cooled Condenser
Air-cooled Condenser Fan Motor (1 pc)
Drier
Solenoid Valve
Strainer
Thermal Expansion Valve
Access Valve
Heat Exchanger
[b] SERVICE INSTRUCTIONS
Always restore the original bindings after servicing the refrigeration circuit. Otherwise, vibration
may cause overstress and damage to the circuit, resulting in refrigerant leak.
After replacing the Evaporator (Drum), Mechanical Seal, Bearing, or Oil Seal, run the icemaker
for 30 minutes to produce ice, check for impurities, and discard.
[c] REFRIGERANT CONTROL (Compressor Cooling)
See “1. WATER AND REFRIGERANT CIRCUIT”.
Fan Cooling
The Fan Motor blows air over the Compressor to release its heat.
[d] REFRIGERANT CONTROL (Ice Production Control)
Fan Speed Control
Increased ice production in a low temperature condition will overload and damage the icemaking
mechanism. To control the ice production, the Controller Board energizes and de-energizes
the Fan Motor to reduce its rotation speed.
[e] REFRIGERANT
The icemaker employs refrigerant R404A which itself is not flammable or poisonous. However,
a small room filled with R404A may cause suffocation with a lack of oxygen. Also, when exposed
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to an open flame, R404A creates Phosgene gas, hazardous in large amounts. Handle the
refrigerant in a well-ventilated area with no flames.
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.
[f] COMPRESSOR
The Compressor absorbs the low-pressure refrigerant gas vaporized in the Evaporator (to reduce
the pressure inside the Evaporator), compresses the refrigerant into high-temperature high-
pressure gas, and sends it out to the Condenser.
The hermetic-type Compressor is efficient in refrigeration, and the refrigeration circuit is designed
to endure long hours of operation. The Compressor is mounted on vibration damping rubber to
prevent transmission of vibration. In case of accidental overload, the Case Thermostat or
Overload Relay will shut down the Compressor. The Reset Button must be pressed to reset the
Overload Relay.
[g] EVAPORATOR (DRUM)
The Evaporator is a drum with shafts at both ends and a refrigerant path between a metallic
exterior and a plastic interior. The refrigerant flows through a very narrow path in the Expansion
Valve with a sudden drop of pressure and evaporates by absorbing heat of vaporization from
the Evaporator. The water supplied inside the Tank holding the Evaporator is deprived of heat
and forms thin ice around the Evaporator, which will be scraped off by the Cutter.
[h] CONDENSER
The Condenser refrigerates and liquefies the high-temperature high-pressure refrigerant gas
discharged from the Compressor into high-pressure liquid refrigerant.
A dirty Condenser will significantly reduce the refrigeration efficiency and performance, and will
also shorten the service life of the components (especially refrigeration circuit). The Condenser
must be cleaned according to the following instructions. The frequency of cleaning depends on
the installation conditions.
Air-cooled Condenser (Fin-and-tube type)
A copper tube is attached on a finned aluminum plate with high heat conductivity to promote
heat radiation, and a Fan Motor is also provided for forced air cooling. A remote type Condenser
is also available to protect the interior from noise of the Fan Motor and temperature rise by heat
radiation.
Use a vacuum cleaner or brush to remove dirt and dust between the fins. Be careful not to bend
the fins.
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[i] CONDENSER COOLING FAN MOTOR
The Fan Motor cools the Air-cooled Condenser and sends air to condense refrigerant gas inside
the Condenser.
[j] DRIER
The Drier uses desiccants (molecular sieves + activated alumina) to absorb moisture in the
refrigeration circuit. The built-in filter also corrects foreign matter in the refrigeration circuit to
prevent troubles with valves clogged with dirt or moisture.
[k] SOLENOID VALVE
The Solenoid Valve is provided for pump down control to prevent refrigerant gas from remaining
inside the Evaporator and causing liquid return at restart.
[l] THERMOSTATIC EXPANSION VALVE
The Expansion Valve throttles high-pressure liquid refrigerant into low-temperature low-pressure
state by adiabatic expansion and maintains the proper amount of refrigerant supply depending
on the Evaporator load. The Thermostatic Expansion Valve controls the valve position to regulate
the superheat (difference between evaporating temperature and suction gas temperature). No
superheat control is available from outside.
To check the Expansion Valve for proper operation, remove the Bulb while the Compressor is
running. If the suction pressure rises, the Expansion Valve is working normally.
Note: Do not leave the Bulb removed for a long time while the Compressor is running. The
Compressor may fail due to liquid return.
[m] ACCESS VALVE
The Access Valve connects the inside and outside of the refrigeration circuit to allow evacuation,
recharge, and pressure measurement.
Note: When replacing (brazing) the Access Valve, remove the valve core to prevent the
rubber part from melting. The valve is sealed by the core only. Always cap the valve while
not in use. Tighten the seal nut to the torque of 9.81 - 12.26Nm to prevent gas leaks.
[n] RECEIVER TANK
The Receiver Tank temporarily stores excess liquid refrigerant which may be caused by a change
in ambient temperature. The Access Valve provided for servicing can also be used to check
the high-side pressure.
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