Hoshizaki America, Inc.
Contents
1. 10 113 PSIG 2 Shut off Valve closed or 2 Open restricted b Water Valve 1 Clogged filter 1 Clean 2 Coil winding opened 2 Replace c Float Switch 1 Contacts fused 1 Replace 2 Clogged 2 Clean d Water Control Relay 1 Bad Contacts Terminal 1 Check for continuity and Nos 1 and 5 replace 2 Contacts fused Terminal 1 Replace Nos 3 and 5 e Bin Control Switch 1 Bad contacts 1 Check for continuity and replace f Ice Making Switch 1 OFF position 1 Move to ON position 2 Bad contacts 2 Check for continuity and replace 7 Ice dispenser will not stop even if out of water a Float Switch 1 Contacts fused 1 Replace 2 Clogged 2 Clean b Water Control Relay 1 Contacts fused Terminal 1 Replace Nos 4 and 6 22 2 LOW ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY 1 Abnormal a Condenser 1 Dirty Air Filter or Condenser 1 Clean refrigeration 2 Bad ventilation 2 Remove anything blocking circuit vents b Thermostatic Expan sion Valve 1 Low side pressure or tem perature exceeding the limit 1 Secure bulb to low side line or replace c Refrigerant Lines 1 Gas leaks 1 Check for leaks with a leak detector Reweld leak replace drier and charge with refrigerant The amount of refrigerant is marked on Nameplate 2 Overcharged 2 Recharge d Compress2. 7 Pull out Spout A from Spout B 8 Remove the Top Panel and Storage Bin Cover See Fig 5 9 Remove the Agitator and Drip Ring Wipe using a clean cloth containing the cleaning solution 42 Middle Front Panel Spout A Spout B 1 Fig 4 5 Storage Bin Cover Bin Control Switch Screw Shutter Assembly Agitator Drip Ring Chute Insulation Extruding Head Fig 5 Auger 43 10 Pour the cleaning solution carefully into the Reservoir through the opening in the center of the Storage bin up to an overflow level Solution that has overflowed can be seen in the Drain Pan 11 While waiting for 10 minutes to start icemaking process wipe the Bin Liner and the Drip Plate using a clean cloth containing the cleaning solution 12 Replace the Drip Ring and Agitator 13 Move the Ice Making Switch and then the Power Switch to the ON position Place the Storage Bin Cover in position and start the automatic icemaking process Run the ice dispenser until it stops automatically 14 Move the Ice Making Switch to the FLUSH position and wait for flush process to begin 60 seconds 15 Pour clean warm water carefully onto the Bin Liner Agitator Drip Ring and into the Reservoir through the opening in the center of the Storage Bin to melt the ice and rinse out the cleaning solution 16 Move the Power Switch to the OFF position 17 Wipe the Storage Bin Cover and Spo
3. 1 Replace b Timer 1 Bad contacts X2 Relay 1 Check for continuity and replace 2 X2 Relay coil winding 2 Replace opened 3 Loose connections 3 Tighten c Motor Protector T Bad contacts 1 Check for continuity and replace d Starter 1 Bad contacts 1 Check for continuity and replace e Starting 1 Defective 1 Replace Capacitor 4 Gear Motor Gear Motor 1 Motor winding opened 1 Replace will not start b Timer 1 Bad contacts X1 Relay 1 Check for continuity and replace c Protect Relay 1 Bad contacts 1 Check for continuity and replace 2 Coil winding opened 2 Replace 3 Loose connections 3 Tighten d Protector 1 Bad Contact 1 Check for continuity and replace e Capacitor 1 Defective 1 Replace 21 PROBLEM POSSIBLE CAUSE REMEDY 5 Fan Motor a Fan Motor 1 Motor winding opened 1 Replace will not start 2 Bearing worn out 2 Replace 3 Wiring to Fan Motor 3 Check for loose connec tion or open and replace 4 Fan blade bound 4 Check and replace b Timer 1 Bad contacts X2 Relay 1 Check for continuity and replace 2 X2 Relay coil winding 2 Replace opened 3 Loose connections 3 Tighten 6 No water or poor flow a Water supply 1 Water failure or pressure too low 1 Wait until water is sup plied or adjust the pressure range within
4. 3 REMOVAL 28 4 REMOVAL AND REPLACEMENT DRIER 102 1 00404 1 a 29 5 REMOVAL AND REPLACEMENT OF THERMOSTATIC EXPANSION VALVE 30 6 REMOVAL AND REPLACEMENT OF PRESSURE SWITCH 31 7 REMOVAL AND REPLACEMENT OF CONTROL WATER VALVE 32 8 REMOVAL AND REPLACEMENT OF FLUSH WATER VALVE 33 9 REMOVAL AND REPLACEMENT OF FLOAT a 34 10 REMOVAL AND REPLACEMENT OF BIN CONTROL SWITCH ASSEMBLY 35 11 REMOVAL AND REPLACEMENT OF STORAGE BIN ASSEMBLY 36 12 REMOVAL AND REPLACEMENT AGITATOR AND DRIP 37 13 REMOVAL AND REPLACEMENT OF EVAPORATORASSEMBLY 38 VI CLEANING AND MAINTENANCE INSTRUCTIONS eene nenne 41 1 PREPARING THE ICE DISPENSER FOR LONG STORAGE 41 2 GLEANINGINSTRUCTIONS uuu ua ua a aa aweka 42 ajJGEEANINGPROCEDURE Wa 42 Ero 45 3 MAI
5. REPLACEMENT OF THERMOSTATIC EKPANSION VALVE IMPORTANT Sometimes moisture in the refrigerant circuit exceeds the Drier capacity and freezes up at the Expansion Valve Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply and unplug the dispenser 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the insulation and the Expansion Valve Bulb on the suction line 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 3 4 PSIG WARNING 1 Do not heat the wall Place a steel barrier for protection 2 Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 7 Install the new Drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 10 Place the Expansion Valve in position 11 Place the new set of Expansion Valve Covers in position 12 Attach the Expansion Valve Bulb to the low side line and secure it with Bulb Holder and Clamps 30 13 Cover the Expansion Valve Bulb tightly with the insulation 14
6. Relay replace 2 No water is a Water Valve Dis 1 Clogged Filter 1 Clean dispensed pensing b Water Dispensing 1 Bad contacts 1 Check for continuity and Switch replace 8 Ice keeps a Shutter 1 Faulty adjustment 1 With Shutter closed lock being dis Shutter in place by pensed securing with two screws at the lower part of Solenoid and two screws under Solenoid b Ice Switch 1 Contacts fused 1 Replace Dispensing Switch 24 4 OTHERS PROBLEM POSSIBLE CAUSE REMEDY 1 Ice dispenser a Bin Control Switch 1 Contacts fused 1 Replace will not stop 2 Out of position 2 Reinstall even if filled b Water Control Relay 1 Contacts fused 1 Replace with ice c Timer 1 Defective 1 Replace 2 Reservoir a Water Supply 1 Water pressure too high 1 If pressure is consistently overflows too high install a pres Water will sure reducing valve not stop b Water Valve 1 Cannot close 1 Clean or replace c Float Switch 1 Bad contacts red and black 1 Check for continuity and leads replace 2 Defective 2 Replace d Water Control Relay 1 Coil winding opened 1 Replace 2 Bad contacts Terminal Nos 2 Check for continuity and 1 and 3 replace 3 A lot of water a Mechanical seal 1 Dirt stuck on seal surface 1 Clean or replace drains from normally less than 2 Worn out 2 Replace Ge
7. and soap bubbles 17 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 18 Remove the four Socket Head Cap Screws at the bottom of the Evaporator 19 Disconnect the Hose from the Evaporator 20 Lift off the Evaporator HOUSING AND MECHANICAL SEAL 21 Remove the four Hexagon Bolts securing the Housing to the Gear Motor 22 Remove the Mechanical Seal fixed on the Housing Note The Mechanical Seal consists of two parts One moves along with the Auger and the other is fixed on the Housing If the contact surfaces of these two parts is worn or scratched the Mechanical Seal may cause water leaks and should be replaced 23 Replace the Bearing inside the Housing using a fitting tool if the Bearing is worn or scratched Note Replacing the Bearing requires a fitting too If one is not available replace the whole Housing Be sure to install the O ring 39 GEAR MOTOR 24 Cut the Gear Motor leads at the wire connector 25 Remove the three Hexagon Bolts securing the Gear Motor on the chassis 26 Remove the Gear Motor 27 Install the new Gear Motor 28 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 29 Check for water leaks WARNING After assembl
8. 91 100 172 78 APPROXIMATE ELECTRIC 70 654 CONSUMPTION 80 660 667 673 90 60 686 1460 100 70 APPROXIMATE WATER 70 31 118 CONSUMPTION PER 24 HR 80 27 103 90 24 91 100 21 78 EVAPORATOR OUTLET TEMP 70 20 7 80 23 5 90 24 34 100 24 4 HEAD PRESSURE 70 217 152 80 251 176 90 285 20 0 100 327 23 0 SUCTION PRESSURE 70 37 26 PSIG kg sq cmG 80 40 28 90 43 30 100 46 32 TOTAL HEAT OF REJECTION 3532 BTU h AT 90 F WT 70 F Note Pressure data is recorded first 5 minutes in freezing cycle The data without marks should be used for reference We reserve the right to make changes in specifications and design without prior notice 3 WIRING DIAGRAM WIRE COLOR CODE BR BROWN BK BLACK DBU DARK BLUE LBU LIGHT BLUE GREY ORANGE PINK RED VIOLET WHITE YELLOW W BK WHITE BLACK W BR WHITE BROWN W BU WHITE BLUE WO WHITE ORANGE WR WHITE RED lt lt b N BK POWER SWITCH 445 174MFD DRAIN WATER VALVE KA2 4 SEQUENCE OF ELECTRICAL CIRCUIT POWER ON WATER STARTS TO BE SUPPLIED TO RESERVOIR AGITATION TIMER ON 2 SEC e 45 120V 60HZ 19 MMC N POWER SWITCH START CAP 145 17 4MFD BN CONTROL SWITCH FLOAT SWITCH DISPENSE WATER VALVE DRAIN WATER VALVE 10 A2A
9. AA0269806 A2AAA0269806 415 120 60 2 18 N POWER SWITCH RESERVOIR FILLS UP GEAR MOTOR TURNS ON START CAP 145 174 DISPENSING BIN CONTROL SWITCH FLOAT SWITCH WATER SWITCH DISPENSE WATER VALVE RATER VALVE 11 yep 115 120 V 60HZ 1 e N POWER SWITCH COMPRESSOR STARTS 60 SEC AFTER GEAR MOTOR BIN CONTROL SWITCH FLOAT_SWITCH WATER SWITCH DISPENSE A WATER YALVE D RATER VALVE D 12 15 120V 60HZ2 10 POWER SWITCH ICE MAKING CONTINUES START CAP OUT TAKEN OUT OF CIRCUIT WATER SWITCH WATER VALVE 13 aes 15 120V 60HZ 19 N POWER SWITCH LAMP BIN CONTROL TRIPS T COMPRESSOR STOPS 90 SEC LATER START CAP 145 17 4MFD BIN CONTROL SWITCH WATER SWITCH WATER VALVE 14 uu 45 420 6 19 POWER SWITCH GEAR MOTOR STOPS 60 SEC AFTER COMPRESSOR START CAP 145 174MFD DISPENSE WATER VALVE 15 a ass 15 120V 60HZ 19 xU N POWER SWITCH DISPENSE ICE BIN CONTROL STILL TRIPPED START CAP 445 174MFD SWITCH 16 ae ee 415 120 60 2 19 N POWER SWITCH DISPENSE WATER BIN CONTROL STILL TRIPPED GEAR MOTOR PRESSURE PROTECT RELAY eS a START CAP 145 174 0 TIMER BOARD I 445 j LU SWITCH s
10. CE FOR REFRIGERANT LINES a REFRIGERANT RECOVERY The icemaker unit is provided with two Refrigerant Access Valves one on the low side and one on the high side line Using proper refrigerant practices recover the refrigerant from these two Access Valves and store it in an approved container Do not discharge the refrigerant into the atmosphere b EVACUATION AND RECHARGE R 404A 1 Attach Charging Hoses a Service Manifold and a Vacuum Pump to the system Be sure to connect charging hoses to both High and Low side Access Valves IMPORTANT The vacuum level and Vacuum Pump may be the same as those for current refrigerants However the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils 2 Turn on the Vacuum Pump Never allow the oil in the Vacuum Pump to flow backward 3 Allow the Vacuum Pump to pull down to a 29 9 Hg vacuum Evacuating period depends on pump capacity 26 4 Close the Low side Valve and High side Valve on the Service Manifold 5 Disconnect the Vacuum Pump and attach a Refrigerant Service Cylinder to the High side line Remember to loosen the connection and purge the air from the Hose See the Nameplate for the required refrigerant charge Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No 700 88 be used 6 A liquid charge is recommended for charging an R 404A system Invert the service cy
11. EGIBEIGATIONS meis etc ec Stay Nes LI 4 1 DCM 270BAH Air cooled 4 Il GENERAL INFORMATION a a a nn annassa 5 Beo TETTE 5 2 OPERATION How it WOIKS KE KIE 6 TECHNICAL INFORMATION 2 000020 0 0 rnnne nnn sese seda 7 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT a aa 7 2 PERFORMANCE DATA Ni 8 3 WIRING DIAGRAM ettet De RE e est E CE Te 9 4 SEQUENCE OF ELECTRICAL CIRCUIT 10 IV SERVICEDIAGNOSIS 5 NYA 21 T iNO IGE PRODU GTION L u unas nn RI AA MKAKA 21 2 LOW IGE PRODUCTION ha 23 EAUETY DISPENSER eed heed WA quna uuu 24 Ads Mery II ER TTE 25 V REMOVAL 5 26 1 SERVICE FOR REFRIGERANTLINES 26 a REFRIGERANT RECOVERY 2865 ses candies RS ER AREE ERR a ede ren eR bro gode qun 26 b EVACUATION AND RECHARGE R 404A 26 2 BRRAZIIN Gist um Soma ea 27
12. Hoshizaki America Inc Cubelet Models DCM 270BAH SERVICE MANUAL of Reliability www hoshizaki com 5 Number 73100 Issued 4 30 2002 Revised 12 15 2003 IMPORTANT Only qualified service technicians should attempt to service or maintain this ice dispenser No service or maintenance should be undertaken until the technician has thoroughly read this service manual HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the dispenser Should the reader have any questions or concerns which have not been satisfactorily addressed please call or write to the HOSHIZAKI Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn HOSHIZAKI Technical Support Department Phone 1 800 233 1940 Technical Service 770 487 2331 Fax 770 487 3360 NOTE To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem Please review this manual It should be read carefully before the ice dispenser is serviced or maintenance operations performed Only qualified service technicians should service and maintain the dispenser This manual should be made available to the technician prior to service or maintenance CONTENTS PAGE SP
13. LACEMENT OF COMPRESSOR IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made Note When replacing a Compressor with a defective winding be sure to install the new Start Capacitor and Start Relay supplied with the re placement Compressor Due to the ability of the POE oil in the com pressor to absorb moisture quickly the Compressor must not be opened more than 15 minutes for replacement or service Do not mix lubricants of different compressors even if both are charged with R 404A except when they use the same lubricant 1 Turn off the power supply and unplug the dispenser 2 Remove the panels 3 Remove the Terminal Cover on the Compressor and disconnect the Compressor Wiring 4 Recover the refrigerant and store it in an approved container 5 Remove the Discharge and Suction Pipes using brazing equipment WARNING When repairing a refrigerant system be careful not to let the burner flame contact the lead wires or insulation 6 Remove the Hold down Bolts Washers and Rubber Grommets 7 Slide and remove the Compressor Unpack the new Compressor package Install the new Compressor 8 Attach the Rubber Grommets of the prior Compressor 9 Sandpaper the Suction Discharge and Process Pipes 10 Place the Compressor in position and secure it using the Bolts and Washers 11 Remove plugs from t
14. NTENANCE INSTRUCTIONS 2000000 0 46 I SPECIFICATIONS 1 DCM 270BAH Air cooled AC SUPPLY VOLTAGE 115 60 1 AMPERAGE 8 5 AT 104 F 40 C WT 80 F 27 C MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE NA APPROKIMATE ICE PRODUCTION i Ibs day kg day za cem Us xe mg Reference without marks SHAPE OF ICE Cubelet compressed flake ice ICE QUALITY Approx 90 Ice 90 70 F Conductivity 200 us cm APPROXIMATE STORAGE CAPACITY 8 8 lbs ELECTRIC amp WATER CONSUMPTION 90 70 F 70 50 F ELECTRIC W kWH 100 lbs 686 7 6 641 5 5 POTABLE WATER 25 6 12 32 8 12 gal 24HR gal 100 lbs EXTERIOR DIMENSIONS WxDxH 16 9 16 x 24 3 16 x 31 7 8 420 x 615 x 809mm EXTERIOR FINISH Stainless Steel plastic top WEIGHT Net 152 lbs 69 kg Shipping 170 lbs 77 CONNECTIONS ELECTRIC Cord Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 MPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger 80 W Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL NWA BIN CONTROL SYSTEM Mechanical Bin Control micro switch COMPRESSOR Hermetic Model ASE24C3E CONDENSER Air cooled Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R 404A 14 8 oz 420g DESIGN PRESSURE High 427 PSIG Low 230 PSIG COMPRESSOR PROTECTION Auto Reset Overload Protector GEAR MOTOR PROTECTION M
15. Place the new Expansion Valve Cover in position 15 Replace the panels in their correct positions 16 Plug in the dispenser and turn on the power supply 6 REMOVAL AND REPLACEMENT OF PRESSURE SWITCH IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply and unplug the dispenser 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the Control Box Cover and disconnect the terminals 5 Remove the Pressure Switch using brazing equipment 6 Braze the new Pressure Switch with nitrogen gas flowing at the pressure of 3 4 PSIG 7 Install the new Drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 10 Replace the terminals and the Control Box Cover in their correct positions 11 Replace the panels in their correct positions 12 Plug in the dispenser and turn on the power supply 31 7 REMOVAL AND REPLACEMENT OF CONTROL WATER VALVE 1 Unplug the icemaker 2 Remove the panels 3 Close the Water Supply Line Shut off Valve 4 Disconnect the terminal from the Control Water Valve 5 Loosen the Fitting Nut on the Control Water Valve Inlets and remove the Control Water Valve Do not lose the Pa
16. Switch to the FLUSH position 2 Press the Push Button to dispense ice and remove all ice from the Storage Bin 3 Turn off the power supply and unplug the dispenser 4 Remove the panels 5 Remove the Storage Bin Cover 6 Remove the Agitator Drip Ring Drip Plate and Shutter Assembly 7 Remove the three Socket Head Cap Screws and lift off the Storage Bin Assembly 8 Install the new Storage Bin Assembly 9 Assemble the removed parts in the reverse order of which they were removed 10 Plug in the dispenser and turn on the power supply 11 Move the Shutter to check for proper operation 12 Move the Ice Making Switch to the ON position 36 12 REMOVAL AND REPLACEMENT OF AGITATOR AND DRIP RING 1 Move the Ice Making Switch to the OFF position 2 Press the Push Button to dispense ice and remove all ice from the Storage Bin 3 Turn off the power supply and unplug the dispenser 4 Remove the Top Panel 5 Remove the Storage Bin Cover 6 Rotate the Agitator counterclockwise and lift off 7 Rotate the Drip Ring about 30 degrees clockwise and lift off 8 Install the new Drip Ring and Agitator 9 Assemble the removed parts in the reverse order of which they were removed 10 Plug in the dispenser and turn on the power supply 11 Move the Ice Making Switch to the ON position 37 13 REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY 1 Move the Ice Making Switch to the OFF position 2 Pre
17. anual Reset Circuit Breaker REFRIGERANT CIRCUIT PROTECTION Auto reset High Pressure Control Switch LOW WATER PROTECTION Float Switch and Timer ACCESSORIES SUPPLIED OPERATING CONDITIONS VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG We reserve the right to make changes in specifications and design without prior notice ll GENERALINFORMATION 1 CONSTRUCTION The Hoshizaki Cubelet Ice Dispenser model DCM 270BAH includes Water Supply Freezer Condensing Storage Dispensing and Control Assemblies Storage Bin Control Box B Assembly Right Panel Ice Shutter Timer Agitation Compressor Condenser Spout Fan Evaporator Reservoir Control Box A X Assembly 7 Adjustable Leg Grille Gear Motor Water Supply Louver and Air Filter Inlet Power Cord Fig 1 Note Adjustable Legs Minimum height 4 Maximum height 5 3 Do not adjust exceeding the above recommendation 2 OPERATION How it works Water flows from the potable water source through the Water Supply Line Shut off Valve enters at the Water Inlet fitting and into the Water Reservoir The Water Reservoir functions to maintain a constant water level inside the Freezer Assembly Water from the Water Reservoir enters at the bottom of the Freezer Heat is removed by the refrigeration process and ice forms inside the Freezer A stainless steel Auger located inside the Freezer is direct driv
18. ar Motor 0 017 fl oz hour Drain Pipe 4 Abnormal a Fan Motor 1 Bearings worn out 1 Replace noise 2 Fan Blade deformed 2 Replace Fan Blade 3 Fan Blade caught on foreign object 3 Remove the object b Compressor 1 Bearings worn out or 1 Replace cylinder valve broken 2 Mounting pad out of posi 2 Reinstall tion c Refrigerant Lines 1 Rubbing or touching lines or 1 Replace other surfaces d Gear Motor Ice 1 Bearing or Gear wear 1 Replace Making damage e Evaporator 1 Scale on inside wall of Freezing Cylinder 1 See chart 2 1 e f Solenoid Shutter 1 Worn out 1 Replace 2 Foreign matter on Plunger 2 Clean surface g Water Valve 1 Foreign matter on Plunger 1 Clean h Extruding Head 1 Bearing worn out 1 Replace i Housing 1 Bearing worn out 1 Replace 25 V REMOVAL AND REPLACEMENT OF COMPONENTS IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after the eguipment is serviced IMPORTANT 1 The Polyol Ester POE oils used in R 404A units can absorb moisture quickly Therefore it is important to prevent moisture from entering the system when replacing or servicing parts 2 Always install a new filter drier every time the sealed refrigeration system is opened 3 Do not leave the system open for longer than 5 minutes when replacing or servicing parts 1 SERVI
19. ckings inside the Fitting Nut 6 Remove the Water Supply Hose from the Control Water Valve 7 Install the new Control Water Valve 8 Assemble the removed parts in the reverse order of the above procedure 9 Open the Water Supply Line Shut off Valve 10 Check for water leaks 11 Replace the panels in their correct position 12 Plug in the icemaker 32 8 REMOVAL AND REPLACEMENT OF FLUSH WATER VALVE 1 Turn off the power supply 2 Remove the panels 3 Close the Water Supply Line Shut off Valve 4 Remove the Clamp and disconnect the Hose from the Flush Water Valve that attaches to the Evaporator Note Water may still remain inside the Evaporator Be sure to drain the water into the Drain Pan 5 Disconnect the Flush Water Valve from the tube connected to the plastic tee leading to the drain hose 6 Disconnect the Terminals from the Flush Water Valve 7 Remove the Flush Water Valve from the Frame or Bracket 8 Connect the new Flush Water Valve back onto the Frame or Bracket 9 Connect the tube from the plastic tee to the new Flush Water Valve 10 Connect the Hose to the Flush Water Valve and secure it with the Clamp 11 Pour water into the Reservoir and check for water leaks on the Flush Water Valve 12 Open the Water Supply Line Shut off Valve 13 Turn on the power supply 14 Move the Flush Switch to the ICE position 15 Check for water leaks 16 Move the Flush Switch to the FLUSH position and mak
20. e sure water is flushing 17 Move the Flush Switch to the ICE position 18 Replace the panels in their correct position 33 9 REMOVAL AND REPLACEMENT OF FLOAT SWITCH WARNING 1 Fragile handle very carefully 2 If the Float Switch works poorly because of scale or other foreign matter install a filter or softener in the water supply line 1 Unplug the dispenser and turn off the power supply 2 Close the Water Supply Line Shut off Valve 3 Remove the panels 4 Flush water out of the system 5 Cut the Float Switch leads at the wire connectors 6 Turn and unfasten the flanged top and remove the Float Switch 7 Install the new Float Switch 8 Assemble the removed parts in the reverse order of which they were removed 9 Open the Water Supply Line Shut off Valve 10 Plug in the dispenser turn on the power supply and check that the Float Switch works normally 34 10 REMOVAL AND REPLACEMENT OF BIN CONTROL SWITCH ASSEMBLY 1 Turn off the power supply and unplug the dispenser 2 Remove the Top Panel 3 Remove the Bin Control Switch from the Storage Bin Cover Twist then pull up 4 Cut the wire leads and remove switch 5 Assemble the replacement switch reversing the procedure used to remove the old switch 8 Plug in the dispenser turn on the power supply and check that the Bin Control Switch works normally 35 11 REMOVAL AND REPLACEMENT OF STORAGE BIN ASSEMBLY 1 Move the Ice Making
21. en 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 cubelet ice compressed ice and then pushed out into the Storage Bin Moving the Power Switch on the bottom left of the Middle Front Panel to the ON position starts the automatic and continuous icemaking process When the Ice Storage Bin is filled with ice the Bin Control Switch will shut off the icemaking process As the ice is removed from the Storage Bin the Bin Control Switch resets automatically and restarts the icemaking process The Agitator in the Storage Bin keeps the ice from clustering so that the ice can move easily through the Spout Ice Push Button Pilot Lamp Water Push Button duy Power Switch Fig 2 TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT CONTROL 1 SPOUT FLOAT 9 SWITCH rh ja WATER i 9 4 w 0 i E SS RESERVOIR N OVERFLOW j GEAR a MOTOR Y Yus WATER a VALVE DRAIN PAN A l CONDENSER ONDENSER FAN MOTOR PnEssURE ACCESS VALVE VALVE COMPRESSOR WATER CIRCUIT REFRIGERANT CIRCUIT 2 PERFORMANCE DATA DCM 270BAH Air cooled APPROKIMATE Ambient Water Temp F ICE PRODUCTION Temp F 90 PER 24 HR 70 259 118 80 228 103 90 201
22. he Suction Discharge and Process Pipes 28 12 Braze the Process Suction and Discharge lines Do not change this order while purging with nitrogen gas flowing at the pressure 3 4 PSIG 13 Install the new Filter Drier 14 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 15 Connect the Terminals and replace the Terminal Cover in its correct position 16 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 17 Replace the panels in their correct positions 18 Plug in the dispenser and turn on the power supply 4 REMOVAL AND REPLACEMENT OF DRIER IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply and unplug the icemaker 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the Drier using brazing equipment 5 Install the new Drier in the direction of the refrigerant flow Use nitrogen gas at the pressure of 3 4 PSIG when brazing the tubings 6 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 7 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 8 Replace the panels in their correct positions 9 Plug in the dispenser and turn on the power supply 29 5 REMOVAL AND
23. ing the Extruding Head be sure to check that the Auger does not come into contact with the inner surface of the Evaporator and that there is not any abnormal noise from the Bearing 30 Turn on the power supply 31 Move the Ice Making Switch to the ON position 40 VI CLEANING AND MAINTENANCE INSTRUCTIONS IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment 1 PREPARING THE ICE DISPENSER FOR LONG STORAGE IMPORTANT When shutting off the ice dispenser for an extended time drain out all water from the water line and remove the ice from the Storage Bin The Storage Bin should be cleaned and dried Drain the ice dispenser to prevent damage to the water supply line at sub freezing temperatures using air or carbon diox ide Shut off the ice dispenser until the proper ambient temperature is resumed 1 Close the Water Supply Line Shut off Valve 2 Move the Ice Making Switch located on the Control to the FLUSH position 3 Press the Push Button for ice dispensing and remove all ice from the Storage Bin 4 Wait until all water is drained out through Drain Pan and move Power Switch to the OFF position 5 Unplug the Ice Dispenser IMPORTANT Before operating the dispenser next time open the Water Supply Line Shut off Valve Note When shutting off the ice dispenser at sub freezing temperatures r
24. linder Open the High side Service Manifold Valve 7 Allow the system to charge with liquid until the pressures balance 8 If necessary add any remaining charge to the system through the Low side Use a throttling valve or liquid dispensing device to add the remaining liquid charge through the Low side access port with the unit running 9 Close the two Refrigerant Access Valves and disconnect the Hoses and Service Manifold 10 Cap the Access Valves to prevent a possible leak 2 BRAZING DANGER Refrigerant R 404A itself is not flammable at atmospheric pressure and temperatures up to 176 F Refrigerant R 4044 itself is not explosive or poisonous However when exposed to high temperatures open flames R 404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere Do not use silver alloy or copper alloy containing Arsenic Do not use R 404A as a mixture with pressurized air for leak testing Refrig erant leaks can be detected by charging the unit with a little refrigerant raising the pressure with nitrogen and using an electronic leak detector Note All brazing connections inside the bin are clear paint coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove coating 27 3 REMOVAL AND REP
25. o Sem DRAIN CONTROL RELAY 17 WIRE DIAGRAM 9 5 20 60 2146 gt POWER SWITCH P ABITATEN THER FLUSH SWITCH ACTIVATED WATER VALVE e WIRE DIAGRAM lt t5 t20 60H2 e N POWER SWITCH FLUSH TIMER ACTIVATED 19 WIRE DIAGRAM To N AGITATIGN TIMER ACTIVATES GEAR MOTOR 20 IV SERVICE DIAGNOSIS 1 NO ICE PRODUCTION operates but PROBLEM POSSIBLE CAUSE REMEDY 1 The ice a Power Supply Cord 1 Broken or loose connection 1 Check for continuity and dispenser will replace not start b Power Switch on 1 OFF position 1 Move to ON position left bottom of Front Panel c Fuse 1 Blown out 1 Check for short circuit and 1A Control Box replace 2 Water Valve Water Supply Line 1 Shut off Valve closed 1 Open 2 Water supply OFF 2 Check and get recom will not start grounded no ice is mended pressure produced b Water Valve 1 Clogged 1 Clean c Water Control Relay Bad contacts Terminal Nos 1 Check for continuity and 4 and 6 replace 2 Coil winding opened 2 Replace 3 Loose connections 3 Tighten d Timer 1 Bad contacts 1 Check for continuity and replace 2 Coil winding opened 2 Replace 3 Loose connections 3 Tighten 4 Defective 4 Replace 3 Compressor a Compressor 1 Motor winding opened or
26. or Motor Protector 1 Overload Protector stops Compressor intermittently 1 Check Condenser and Fan Motor e Inside wall of Evaporator 1 Scale on inside wall of Freezing Cylinder 1 Remove Auger use Hoshizaki Scale Away or LIME A WAY solution to clean periodically If water is found to sur pass the following levels install a conditioner Hardness 50 ppm Silica 30 ppm Condensing Condenser 1 Dirty Air Filter or Condenser 1 Clean temperature 2 Bad ventilation 2 Remove anything blocking too high vents 3 Ambient temperature too high 3 Check ventilation and location and change as needed 4 Less than 6 clearance 4 Allow proper clearance for rear sides and top ventilation b Fan Motor 1 Fan revolving too slowly 1 See chart 1 5 a 3 Poor water flow a Water supply 1 Water pressure too low 1 See chart 1 6 a 23 3 FAULTY DISPENSER PROBLEM POSSIBLE CAUSE REMEDY 1 No ice is a Storage Bin 1 Ice block or bridge 1 Remove all ice from dispensed Storage Bin when not using ice dispenser for a long time b Agitator 1 Deformed due to ice block 1 Replace or bridge c Solenoid 1 Coil winding opened 1 Replace d Ice Switch or Dis 1 Bad contacts 1 Check for continuity and pensing Switch replace e Ice Dispensing 1 Bad contacts 1 Check for continuity and
27. position Reattach the Bin Control Switch to the Storage Bin Cover After water has drained out through the Drain Pan open the water supply line shut off valve and move the Ice Making Switch to the ON position Run the ice dispenser for 30 minutes Move the Ice Making Switch to the FLUSH position and let all water drain out through the Drain Pan Press the ICE Push Button and remove all ice from the Storage Bin Place the Top Panel in position Move the Ice Making Switch to the ON position and start the automatic and continuous icemaking process 45 2 MAINTENANCE INSTRUCTIONS IMPORTANT This ice dispenser must be maintained individually referring to the instruction manual and labels provided with the ice dispenser 1 Stainless Steel Exterior To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up 2 Air Filter See Fig 6 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 ice dispenser s performance will be reduced Check the filter at least twice a month When clogged use warm water and a neutral cleaner to wash the filter 3 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
28. ss the Push Button to dispense ice and remove all ice from the Storage Bin 3 Turn off the power supply and unplug the dispenser 4 Flush all water out of the system 5 Remove the panels 6 Remove the Storage Bin Assembly See 11 REMOVAL AND REPLACEMENT OF STORAGE BIN ASSEMBLY EXTRUDING HEAD 7 Lift off the Extruding Head 8 Replace the Bearing inside the Extruding Head if it is worn or scratched Note Replacing the Bearing requires a fitting tool If one is not available replace the whole Extruding Head AUGER 9 Lift up and turn the Auger until it comes off If the area in contact with the Bearings worn out or the Blade is scratched replace the Auger EVAPORATOR Note Skip the following steps 10 through 17 when the Evaporator does not need replacement 10 Recover the refrigerant and store it in an approved container WARNING Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 11 Remove the Expansion Valve Cover 38 12 Remove the Insulation and the two Clamps on the Expansion Valve Bulb 13 Disconnect the brazing connections of the Expansion Valve and the Copper Tube Low Side from the Evaporator using brazing equipment 14 Braze the new Evaporator with nitrogen gas flowing at the pressure of 3 4 PSIG 15 Replace the Drier 16 Check for leaks using nitrogen gas 140 PSIG
29. the ice dispenser Air Filter Fig 6 46
30. un the dispenser with the Water Drain outlet SEA Supply Line Shut off Valve closed and blow out the water inlet line by using air pressure Fig 3 Drain Valve To approved floor drain 41 2 CLEANING INSTRUCTIONS IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the eguipment 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 To prevent injury to individuals and damage to the ice dispenser do not use ammonia type cleaners 3 Always wear liquid proof gloves for safe handling of the cleaning and sanitizing solutions This will preventirritation in case the solution contacts the skin CLEANING PROCEDURE 1 Close the Water Supply Line Shut off Valve 2 Dilute approximately 6 fl oz of recommended cleaner Hoshizaki Scale Away or LIME A WAY manufactured by Economics Laboratory Inc with 1 gal of water Move the Ice Making Switch located on the Control to the FLUSH position 4 Press the ICE Push button and remove all ice form the Storage Bin 5 After water has drained out through the Drain Pan move the Power Switch to the OFF position 6 Remove Spouts A and B by removing the Thumbscrew sliding the Spouts back ward and then pulling them down See Fig 4
31. uts A and B using a clean cloth containing the cleaning solution 18 Rinse the wiped parts with water Be careful not to wet the Bin Control Switch on the Storage Bin Cover CAUTION Do not use ice produced with cleaning and sanitizing solutions Be sure none remains in the Storage Bin 44 b SANITIZING PROCEDURE 1 Dilute approximately 1 5 fl oz of a 5 25 Sodium Hypochlorite solution chlorine bleach with 3 gal of water Pour the sanitizing solution carefully into the Reservoir through the opening in the center of the Storage Bin up to an overflow level Wait for 10 minutes to start the icemaking process Move the Ice Making Switch to the ON position and start automatic icemaking process Run the ice dispenser until it stops automatically Move the Ice Making Switch to the FLUSH position Wipe the Bin Liner and the Drip Plate using a clean cloth containing the sanitizing solu tion Pour clean warm water carefully onto the Bin Liner and into the Reservoir through the opening in the center of the Storage Bin to melt the ice and rinse out the sanitizing solution Be careful not to wet the Bin Control Switch on the Storage Bin Cover Remove the Bin Control Switch from the Storage Bin Cover and immerse the Storage Bin Cover Agitator Drip Ring and Spouts A and B in the sanitizing solution Rinse the parts sanitized above using water Place the parts rinsed above back in
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