Service Manual
Contents
1. 25 b Evaporator is Frozen 28 Low Ice Production siiscciccsiectccctornsnancnsddaxtaxxtxsnenanananetdiciatncesmsnensndsthexdencnduinenanextontden 29 ETT TO 29 NR 30 30 V Removal and Replacement of Components 32 A Service for Refrigerant Lines 32 1 Refrigerant PRO COV IY etin rei od scant bie d or dnd ed ROO eco 32 2 Evacuation and Recharge 404 32 B 33 C Removal and Replacement of 33 D Removal and Replacement of 34 E Removal and Replacement of Expansion 35 F Removal and Replacement of Hot Gas 35 Removal and Replacement of 36 H Removal and Replacement of 37 Removal and Replacement of Thermistor 38 J Removal and Replacement of Fan 00000000 38 Removal and Replacement of Inlet Water Valve 392. 6 y Bi 0 50 ele vol 354 YOLSIWNNJHL W 019103 JILINDYW y Eo M Wiz O QNOD 101 STIS INO L 03412 68 T dv BNIS 31815 805538407 18 9 o 353490 ET 04105 UAL LNHS dv ya AWZ MY M 010 39 Vei 0408049 33 0 45 ama LH9N NgT MOTIBA 130A A 3119 Mavanga d AVUD AD JONVUO 0 O3 VTE 3lHM M 98 300 4010 WUNLVN dd 8 89 20 C Timing Chart When control switch is turned OFF pressure switch is OFF or thermistor temperature exceeds t1 From harvest cycle To harvest cycle If float switch is OFF Temp Too Low Temp Too Hi Temp EE Thermistor t gt CE Tum ON Float Switch OF L Compressor ______ Control Switch in ON Crankcase Heater Remote Only Bin 1 IB Icemaking Thermostat HESS p E ON F Max freeze Pressure ____ timer setting Pump Motor Switch ON VLLL I 4 Overheat Reset Fan Motor ON amp Line Valve Fan Motor ON Condenser 4 ON Water Valve OFF 4 ON Hot Gas Valve OFF 1 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See II C 3 Controls and
3. Removal and Replacement of Pump 39 M Removal and Replacement of Spray 40 N Removal and Replacement of Gear Motor 40 Removal and Replacement of Dispense 41 P Removal and Replacement of Solenoid sss 41 VI Cleaning and Maintenance 4040 00 0 42 Cleaning Instructions 42 1 Cleaning Procedure 2 42 2 Sanitizing Procedure 1 43 3 Cleaning Procedure vanes 44 4 Sanitizing Procedure 44 B Maintenance Instr cllOlIS 45 DN Sacs PTT Tm 45 A dl 45 Bo MU Si 45 C Preparing the Icemaker for Long 0 4 0400001 45 Specifications A DKM 500BAH AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY APPROXIMATE ICE DISPENSING SPEED ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS
4. pezibjeue SHES Jeuil 1 Sep o OL 10 G Z 4 08S 02 01 10 AG S 4 01 1340 AM sse JO Ox 6 senunuoo AM uedo S 4 3 Nd ASH 2 6 4 87 Seuoeoi peziBjeue ADH peziBieu3 AM puooes dw JO SIWIOUL pezibieue ajoAo 799 senunuoo dwog 4 suifeq dnes eniu HS 208 2 40 sdois Nd 2945 8 4 4 pesop 5 4 lt pesop 5 4 102u05 JO4 UO09 Ul ut S d gt 9Jo o JO seinuiu 161 yew Anu 1015101901 utum umop inus UBD e 1114 2 euin ezeej Og SUN eet MNEs L 1no duing rl sejnuiu 9 19 UI WNWIXEN e sdaig 9 9 2 2 4 2 9 9 2 1S9AJEH 2 EN 1ueuoduio pue eya eouenbes HYgO00S INNG Control Board A HOSHIZAKI exclusive solid state control is employed in the DKM 500BAH Crescent Cube Icemaker Dispenser All units are pretested and factory adjusted CAUTION 1 Fragile handle very carefully A control board contains in
5. valve connection or open and replace f Ice Cube Guide 1 Out of position and ice 1 Place in position trapped 9 Water Supply Line 1 Too small requires 1 Increase water line size 3 8 OD line dedicated per machine h Water Filter 1 Flow rate too small 1 Replace with filter that has larger flow rate c Low Ice Production Possible Cause 1 Freeze cycle time is a See chart 1 a 3 and check dirty air filter or condenser ambient or water long temperature water pressure and refrigerant charge b See chart 1 b 1 and check float switch inlet water valve and control board Check pump hot gas valve expansion valve refrigeration check valve and compressor 2 Harvest cycle time is a See chart 1 b 2 and check control board thermistor evaporator ambient and or water temperature water supply line inlet water valve and hot gas valve d Abnormal Ice Possible Cause 1 Small cubes Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin b See chart 1 a 5 and check water supply line inlet water valve water system pump motor and control board 2 Cloudy or irregular a See chart 1 b 1 and 1 b 3 and check float switch inlet water valve control cubes board spray tubes water system refrigerant charge and expansion valve b Spray Guide c Water Quality 1 High hardness or 1 Install a water softener or contains i
6. too short orifice and water level in water tank too low c Water System 1 Water leaks 1 Check connections for water leaks and replace 2 Clogged 2 Clean d Pump Motor 1 Motor winding opened 1 Replace 2 Bearing worn out 2 Replace 3 Wiring to pump motor 3 Check for loose connection or open and replace 4 Defective capacitor 4 Replace 5 Defective or bound 5 Replace and clean impeller e Control Board 1 Defective 1 See 1 5 Control Board Check Procedure 6 Fan motor will a Fan Motor 1 Motor winding opened 1 Replace not start or is not operating 2 Bearing worn out 2 Replace 3 Wiring to fan motor 3 Check for loose connection or open and replace 4 Defective capacitor 4 Replace 5 Fan blade bound 5 Check and replace 27 b Control Board 1 Defective 1 See 1 5 Control Board Check Procedure 7 All components a Refrigerant 1 Undercharged 1 Check for leaks and run but no ice is recharge produced 2 Air or moisture 2 Replace drier and trapped recharge b Compressor 1 Defective valve 1 Replace c Hot Gas Valve 1 Continues to open 1 Check and replace freeze cycle d Inlet Water Valve 1 Water valve is wide 1 Check for water leaks with open during freeze icemaker off b Evaporator is Frozen Up Possible Cause 1 Freeze cycle time 1 a Float Switch 1 Leads short circuit 1 Check and replace too long defective
7. 9 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 10 Cut the leads of the solenoid allowing enough lead length to reconnect using closed end connectors 11 Connect the new solenoid leads 12 13 14 Attach the solenoid to the valve body and secure it with a screw Replace the panels in their correct positions Turn on the power supply Removal and Replacement of Evaporator IMPORTANT 1 Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repairs or replacement have been made 2 Because the pipes in the evaporator section are specially coated to resist corrosion it is important to make the new evaporator inlet and outlet piping connections outside the evaporator section as described below 1 Turn off the power supply 2 Remove the outer panels and the evaporator insulation panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Recover the refrigerant and store it in an approved container 4 Remove the spray tubes and the insulations at the U shaped notch where the refrigeration tubings go through the molded chassis 5 Remove the insulation tube and disconnect the evaporator inlet piping at the tee before the expansion valve Disconnect the evaporator outlet piping before the heat exchanger 36 6
8. 10th cycle Pump Out Frequency Control dip switch 5 amp 6 The pump motor drains the water tank at the frequency set by the pump out frequency control The pump out frequency control is factory adjusted to drain the water tank every 10 cycles and no adjustment is required However where water quality is bad and the icemaker needs a pump drain more often the pump out frequency can be adjusted as shown in the table below f Freeze Timer dip switch 9 amp 10 CAUTION Adjust to proper specification or the unit may not operate correctly The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze up issues Upon termination of freeze timer machine initiates the harvest cycle After 2 consecutive timer terminations machine will shut down possibly indicating a problem The freeze timer is factory adjusted and no adjustment is required Time Lor or e 5 7 0 _ ON 60 g Bin Control CAUTION Dip Switch No 7 must be set to the ON position If No 7 is set to the OFF position the machine will run continuously causing a freeze up condition This machine uses a lever actuated proximity switch mechanical bin control to control the ice level in the storage bin No adjustment is required The bin control is factory adjusted 1 Explanation of Operation A resistor wire harness connects the bin control to the K4 connector on the control
9. Leads opened or 2 Check and replace start defective switch 3 Float does not move 3 Clean or replace freely b Control Board 1 Defective 1 See II C 5 Control Board Check Procedure 3 Compressor will a Magnetic Contactor 1 Bad contacts 1 Check for continuity and not start or stops replace operating 2 Coil winding opened 2 Replace b Start Capacitor or Run 1 Defective 1 Replace Capacitor Internal Overload 1 Loose terminal 1 Tighten or replace Protector Open check 1 through 3 to the right 2 Voltage 2 Check and correct and d through f below 3 Dirty condenser d Starter 1 Check and replace 2 Coil winding opened 2 Replace e Compressor 1 Wiring to compressor 1 Check for loose connection or open and replace 2 Defective 2 Replace 3 Protector tripped 3 Reduce temperature f Control Board 1 No power to contactor 1 See 5 Control Board Check Procedure 4 Water continues to a Inlet Water Valve 1 Diaphragm does 1 Check for water leaks with be supplied in freeze close icemaker off cycle b Control Board 1 Defective 1 See II C 5 Control Board Check Procedure 5 No water comes from a Water Supply Line 1 Water pressure too 1 Check and get spray tubes Water low and water level in recommended pressure pump will not start or water tank too low freeze cycle time Inlet Water Valve 1 Dirty mesh filter or
10. careful to prevent damage to the leads Secure it using the thermistor holder and recommended foam insulation 10 Secure the insulation using the plastic cable ties 11 Connect the thermistor leads through the bushing of the control box to the K3 connector on the control board Note Do not cut the leads of the thermistor while installing it 12 Replace the control box cover and the panels in their correct positions 13 Turn on the power supply J Removal and Replacement of Fan Motor Note When replacing a fan motor with defective winding it is recommended that a new capacitor be installed 1 Turn off the power supply 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panes 3 Disconnect the fan motor wiring harness from the back of the control box Remove the four bolts securing the fan motor assembly to the floor of the machine then remove the assembly 4 Remove the fan motor from the fan motor bracket 5 Remove the fan blade from the old fan motor and attach it to the new fan motor 6 Install the new fan motor and replace the removed parts in the reverse order of which they were removed 7 Replace the panels in their correct positions 8 Turn on the power supply K Removal and Replacement of Inlet Water Valve 1 Turn off the power supply 2 Close the water supply line shut off valve 3 Remove the panels Be sure to disconnect the dispense s
11. made available to the technician prior to service or maintenance CONTENTS nr DERE aU E OO LEON A 9 110 re 5 of CDI MD cei ciated ety 7 Mh Dries Minute IMG CN cet 7 Harvest Cycle 7 SEIN Mem 7 coe ED 7 Normal Harvest Oa DO 7 C Control Board 9 We Control Board Layout E 10 2 URN eee es 11 a Maximum Water Supply Period 6 11 b Harvest Backup Timer and Freeze 11 c High T mperalure Salely 11 d Low Water Safety 11 e High Voltage and Low Voltage 4 11 f LED Lights and Audible Alarm 12 Controls amd Adjustments aa 13 Default Dip Switch Sell aea teo ae 13 Harvest Control s Thermistor sessi uera E ERR DM 13 c Harvest Timer dip switch 1 amp aUe 14 d Pump Out Timer dip switch 3 amp 4 14 e Pump Out Frequency Control dip swit
12. motor does not run check the circuit service relay and capacitor Check for proper voltage If water does not pump out remove the drain valve and check clean the valve assembly 7 Normal Harvest Cycle same as the initial harvest cycle Return to step 4 Note Unit continues to cycle until bin control is satisfied or power is switched OFF The pump out cycle can be adjusted to occur every cycle or every 2 5 or 10 cycles The factory default is every 10 cycles The unit always restarts at the 1 minute fill cycle B Diagnostic Charts 1 Ice Making a No Ice Production 1 The icemaker will not a Power Supply b Fuse Inside fused disconnect if any c Control Switch d Bin Control See the information to the right and also see 4 Bin Control Troubleshooting e High Pressure Control 1 OFF position 1 Move to ON position 3 Bad contacts 3 Check for continuity and replace 4 Voltage too high 4 Check and get recommended voltage 1 Blown 1 Check for short circuit and replace 1 OFF position 1 Move to ICE position 2 Bad contacts 2 Check for continuity and replace 1 Tripped with bin filled 1 Remove ice with ice 2 Bad contacts stuck 2 Check for continuity and open replace 3 Resistor wire harness 3 Check resistance Should be approximately 7 9 KO when calling for ice proximity switch closed 1 Bad contacts 1 Check for continuity and replace
13. power supply for 2 minutes Move the service switch to the DRAIN position Replace the front panel in its correct position 35 Turn off the power supply 36 Remove the front panel 37 Repeat the above steps 22 through 36 three more times to rinse thoroughly then proceed to 2 Sanitizing Procedure 2 Sanitizing Procedure Icemaker 1 Dilute approximately 1 0 fl oz of a 5 25 sodium hypochlorite solution chlorine bleach with 2 gallons of warm water 2 Pour the sanitizing solution into the water tank 3 Move the service switch to the WASH position 4 Replace the front panel in its correct position 5 6 7 Remove the front panel Turn on the power supply and start the sanitizing process Turn off the power supply after 15 minutes 8 Move the service switch to the DRAIN position 9 Replace the front panel in its correct position 43 10 11 12 13 Turn on the power supply for 2 minutes Turn off the power supply Remove the front panel SS wa Repeat steps 22 through 36 in Cleaning Procedure two times to rinse thoroughly 14 Move the control switch to the ICE position then proceed to 3 Cleaning Procedure Bin 3 Cleaning Procedure Bin 1 Dilute approximately 5 fl oz of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 1 gallon of warm wa
14. switch 2 Float does not move 2 Clean or replace freely b Inlet Water Valve 1 Diaphragm does not 1 Check for water leaks with close icemaker off Control Board 1 Defective 1 See 1 5 Control Board Check Procedure 2 All formed on 1 Scaled up evaporator does p water Supply Line 1 Water pressure too 1 Check and get fall into bin in harvest low recommended pressure cycle y c Water Filter System 1 Dirty Restricted 1 Replace filter d Inlet Water Valve 1 Dirty mesh filter or 1 Clean orifice 2 Diaphragm does not 2 Check for water leaks with close icemaker off e Ambient and or water 1 Too cool 1 Increase temperature temperature f Thermistor 1 Out of position or 1 See V H Removal loose attachment and Replacement of Thermistor g Control Board 1 Harvest timer is set 1 Adjust longer referring too short to II C 3 Controls and Adjustments c Harvest Timer 2 Defective 2 See II C 5 Control Board Check Procedure 3 Other a Spray Tubes 1 Clogged 2 Out of position 2 Place in position p Water System c Refrigerant 1 Undercharged 1 Check for leaks and recharge 28 Possible Cause d Expansion Valve 1 Bulb out of position or 1 Place in position loose attachment 2 Defective 2 Replace e Hot Gas Valve 1 Coil winding opened 1 Replace 2 Plunger does not 2 Replace move 3 Wiring to hot gas 3 Check for loose
15. 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 cylinder Open the high side service manifold valve 7 Allow the system to charge with liquid until the pressures balance 32 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 B Brazing DANGER Refrigerant R 404A itself is not flammable at atmospheric pressure and temperatures up to 176 F 80 C Refrigerant R 404A 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 3 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
16. 2 Dirty air filter or 2 Clean condenser 3 Ambient temperature 3 Reduce temperature too warm 5 4 Refrigerant 4 Recharge overcharged 5 Fan not operating 5 See chart 1 a 6 6 Refrigerant line or 6 Clean and replace drier components plugged f Transformer 1 Coil winding opened 1 Replace or shorted g Wiring to Control Board 1 Loose connections or 1 Check for continuity and open replace h Thermistor 1 Leads shorted or 1 See II C 3 Controls and opened and high Adjustments b Harvest temperature or harvest Control backup timer safety operates 1 beep or 2 beep alarm i Hot Gas Valve 1 Continues to open 1 Check for hot gas valve in freeze cycle and stuck open and replace freeze timer safety operates 3 beep alarm j Water Supply Line 1 Water supply off and 1 Check and get water supply cycle recommended pressure does not finish k Inlet Water Valve 1 Mesh filter or orifice 1 Clean gets clogged and water supply cycle does not finish 2 Coil winding opened 2 Replace 3 Wiring to water valve 3 Check for loose connection or open and replace Control Board 1 Defective or in alarm 1 1 5 Control Board Check Procedure m Control Switch 1 SERVICE position 1 Move to ICE position 2 Check and replace 2 Water continues to Float Switch 1 Connector 1 Place in position be supplied and the disconnected icemaker will not 2
17. Adjustments 21 To stand by cycle When control switch is turned OFF pressure switch is OFF or thermistor temperature exceeds 11 To freeze cycle From freeze cycle Too Low Temp Harvest include drain 1 Thermistor Temperature Float Switch Crankcase Heater Remote Only Switch in Icemakin WASH 5 Pump Motor 1 21 LZ NI bd amp Line FT Fan Motor Condenser OF Water Valve 2 Hot Gas Valve 1 The pump motor waits for 2 seconds before starting a drain cycle See II C 3 Controls and Adjustments 2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See II C 3 Controls and Adjustments 22 Performance Data 1 DKM 500BAH APPROXIMATE ICE AMBIENT TEMP WATER TEMP F C PRODUCTION PER 24 HR CFPC 50 10 90 32 70 21 80 27 90 32 Ibs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 m day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG 100 38 TOTAL HEAT OF REJECTION 8098 BTU h AT 90 F 32 C WT 70 F 219 Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold s
18. Hoshizaki America Inc Crescent Cube lcemaker Dispenser Model DKM 500BAH A Superior Degree Service Manual of Reliability www hoshizaki com evercheck HOSHIZAKI ISO 9001 Number 73138 Issued 9 20 2006 IMPORTANT Only qualified service technicians should attempt to service or maintain this unit No such 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 unit Should the reader have any questions or concerns which have not been satisfactorily addressed please call write or send an e mail message 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 1 800 843 1056 770 487 3360 E mail techsupport hoshizaki com Web Site www hoshizaki com 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 unit is serviced or maintenance operations are performed Only qualified service technicians should service and maintain the unit This manual should be
19. Remove the pop rivets securing the evaporator then lift out the evaporator 7 Install the new evaporator 8 Install the new drier 9 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 10 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 11 Replace the removed parts in the reverse order of which they were removed 12 Replace the evaporator insulation panels and the outer panels in their correct positions 13 Turn on the power supply H Removal and Replacement of Condenser 1 Turn off the power supply 2 Remove the panels including the rear panel next to the condenser Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Recover the refrigerant and store it in an approved container 4 Disconnect the fan motor wiring harness from the back of the control box Remove the four bolts securing the fan motor assembly to the floor of the machine then remove the assembly 5 Disconnect the condenser inlet and outlet piping 6 Remove the screws securing the condenser assembly then remove the assembly 7 Remove the shroud from the old condenser and attach it to the new condenser 8 Install the new condenser 9 Install the new drier 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 11 Evacuate the system and charge it with refrigerant See the nameplate for the required re
20. SIG 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 Turn on the power supply 34 Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigeration 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 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 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 to 4 PSIG WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 121 C 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 th
21. WxDxH EXTERIOR FINISH INTERIOR FINISH INSULATION WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED OPERATING CONDITIONS 115 60 1 13 3 A 5 Min Freeze 104 F WT 80 F 15A 15A Ambient WATER TEMP F Temp F 50 70 90 70 466 211 448 203 420 191 80 453 205 425 193 395 179 90 448 203 406 184 376 170 100 390 177 399 181 348 158 Crescent Cube 7 2 lbs 3 2 kg 360 pcs 200 Ibs 91 Kg 13 Ibs min 6 kg min 90 70 F 70 50 F 1150 6 8 1049 5 4 66 16 3 110 23 6 30 x 28 x 77 With 6 Flanged Legs Stainless Steel Galvanized Steel Rear Polyethylene 1 pc Mold Polyurethane Foam Net 385 Ibs 175 kg Shipping 410 Ibs 186 kg Cord Connection Inlet 1 2 FPT Outlet 3 4 FPT x2 Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow N A Proximity Switch with Delay Hermetic Model RS55C2E CAA 219 Air cooled Fin and tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 2lbs 907g High 467 PSIG Low 170 PSIG High Voltage Cut out I
22. a white wire place the switch in the C position If this switch is placed in the wrong position either the compressor contactor will remain energized with the control switch OFF or the unit will not start The dip switches should be adjusted to the factory default settings as outlined in this manual 8 must remain in the OFF position D Switches Two control switches are used to control operation These switches are referred to as the control switch and the service switch and are located on the control box 1 Control Switch The control switch has three positions OFF for power off ICE for icemaking and SERVICE to activate the service switch 2 Service Switch When the control switch is in the SERVICE position the control switch supplies power to the service switch and the machine is in service mode The service switch has three positions DRAIN CIRCULATE and WASH See the information below for details of each function Note 1 When the service switch is activated power is supplied to the water pump in all three positions 2 When the control switch is in the OFF position or in the ICE position the service switch has no power and can be left in any position a DRAIN This model utilizes a pump out drain system When the service switch is active and placed in the DRAIN position power is supplied to the pump service relay and drain valve 17 b CIRCULATE When the service switch is active and placed in the CIRCULATE positio
23. ace the front panel in its correct position 7 Turn on the power supply for 2 minutes 8 Turn off the power supply 9 Remove the front panel 10 Disconnect the bin control connector Remove the three thumbscrews securing the bin cover and remove the bin cover with the bin control attached 11 12 13 14 Pour the cleaning solution into the water tank Move the service switch to the WASH position Box Replace the front panel in its correct position Turn on the power supply and start the washing process 42 15 Turn off the power supply after 30 minutes 16 Remove the front panel 17 Move the service switch to the DRAIN position 18 Replace the front panel in its correct position 19 Turn on the power supply for 2 minutes 20 Turn off the power supply 21 Remove the front panel 22 Move the control switch to the ICE position 23 Replace the front panel in its correct position 24 Turn on the power supply to fill the water tank with water 25 Turn off the power supply after 3 minutes 26 Remove the front panel 27 Move the control switch to the SERVICE position Then move the service switch to the WASH position 28 Replace the front panel in its correct position 29 Turn on the power supply to rinse off the cleaning solution 30 Turn off the power supply after 5 minutes 31 Remove the front panel 32 33 34 Turn on the
24. alues Normal reading is within 3 5 to 7 Replace the thermistor if it exceeds the normal reading c Harvest Timer dip switch 1 amp 2 The harvest timer starts counting when the thermistor reads 48 F 9 C at the evaporator outlet No adjustment is required under normal use as the harvest timer is adjusted to the suitable position However a setting longer than the factory setting may be advised in cases where the flush provided at harvest needs to be prolonged for extra cleaning Before changing this setting call the HOSHIZAKI Technical Support Department at 1 800 233 1940 for recommendations Keep in mind that setting the harvest timer to a longer setting will decrease 24 hour production Tine seconds Lor or eo ow d Pump Out Timer dip switch 3 amp 4 When a freeze cycle is completed the pump motor stops and the icemaker resumes operation in 2 seconds Then during cycles when a pump out is called for the pump motor drains the water tank for the time determined by the pump out timer The pump out timer also acts in place of the harvest timer during cycles with a pump out The pump out timer is factory adjusted and no adjustment is required T1 Time to drain the water tank T2 Harvest timer at pump out Pump out always occurs on the 2nd harvest after startup Then depending on the pump out frequency control setting dip switch 5 amp 6 pump out occurs every cycle or every 2nd 5th or
25. as a low water safety to protect the water pump WV will remain energized through additional 1 minute cycles until water enters the sump and F S closes 2 Initial Harvest Cycle LEDs 1 4 and 2 are on WV remains open Comp energizes HGV opens and harvest begins As the evaporator warms the thermistor located on the suction line checks for a 48 F 9 C temperature When 48 F 9 C is reached a 3 9 signal turns the harvest over to the adjustable harvest timer which is factory set for normal conditions The timer has settings of 60 90 120 and 180 seconds dip switch 1 amp 2 When the harvest timer completes its count down the harvest cycle is complete and the freeze cycle starts The minimum total time allowed by the board for a complete harvest cycle is 2 minutes 3 Freeze Cycle LED 1 is on Comp continues to run PM and FMS energize HGV and WV close and the freeze cycle starts For the first 5 minutes the control board will not accept a signal from F S This 5 minute minimum freeze acts as a short cycle protection At the end of 5 minutes F S assumes control As ice builds on the evaporator the water level in the sump lowers The freeze continues until F S opens and terminates ice production 4 Pump Out Cycle LEDs 1 3 and 2 are on Comp continues to run HGV opens and FMS de energizes PM stops for 2 seconds SR energizes restarting PM and taking water from the sump and forcing it to go through DV and down the drain W
26. as a mixture with pressurized air for leak testing Refrigerant leaks can be detected by charging the unit with a little refrigerant raising the pressure with nitrogen and using an electronic leak detector Note Because the pipes in the evaporator case are specially coated to resist corrosion it is important to make connections outside the evaporator case when possible If it is necessary to braze inside the evaporator case use sandpaper to remove the coating from the brazing connections before unbrazing the components C Removal and Replacement of Compressor IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Note When replacing a compressor with a defective winding be sure to install the new start capacitor and start relay supplied with the replacement compressor Due to the ability of the POE oil in the compressor 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 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Recover the refrigerant and store it in an approved container 33 4 Remove the terminal cover on the compressor and disconnect the compressor wiring 5 Remove the discharge and sucti
27. auses excessive voltage 147Vac 5 or more on the control board the high voltage cut out shuts down the circuit in 3 seconds and the icemaker automatically stops The control board will signal this problem using 7 beeps every 3 seconds The icemaker also automatically stops in cases of insufficient voltage 92Vac 5 or less The control board will signal this problem using 6 beeps every 3 seconds When the proper supply voltage is resumed the icemaker automatically starts running again 11 f LED Lights and Audible Alarm Safeties The red LED indicates proper control voltage and will remain on unless a control voltage problem occurs At startup a 5 second delay occurs while the board conducts an internal timer check A short beep occurs when the power switch is turned OFF The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below Note that the order of the LEDs from the outer edge of the board is 1 4 3 2 For more information see Sequence of Operation Energized Time LEDs are On Sequence Step eg Components Win Ag 1 Minute Fill Cycle 4 160 Harvest Cycle 1 4 and2 WV HGV pres omnee to 5 minutes Comp Comp PM Freeze Cycle FMS 3 and2 HGV PM SR DV 5 minutes freeze timer 30 to 35 minutes setting m The built in safeties shut down the unit and have alarms as follows No of Type of Alarm High Evapora
28. board When the bin control is calling for ice proximity switch closed a 7 9 KQ reading is sent to the control board to continue operation When the bin control is activated in the bin full position proximity switch open a 15 8 KQ signal is sent to the control board to 15 shut down the unit However to prevent incomplete batches of ice from forming on the evaporator the control board will only shut down the machine within the first 5 minutes of the freeze cycle If ice pushes the lever in after the first five minutes of the freeze cycle the control board will allow the machine to complete the freeze cycle and the following harvest cycle before shutting down the machine Dip switch number 7 must be in the ON position for the control board to receive input from the bin control 4 Bin Control Troubleshooting a Machine Will Not Start 1 Move dip switch no 7 to the OFF position If the machine starts up within a few seconds the bin control is the likely problem If the machine does not start up refer to section IV Service Diagnosis to verify that non bin control related issues are resolved 2 Check to make sure shipping tape has been removed and the wires are connected properly 3 Check to make sure no obstruction prevents the lever from moving to the bin empty position 4 Check proximity switch continuity to make sure it is not stuck open b Machine Will Not Shut Off 1 Refer to Section IV Service Diagnosis to veri
29. ch 5 4 6 15 f Freeze Timer dip switch 9 amp 10 15 PR 15 a Bin Troubleshooting s A 16 Machine Will Not teda aga M bees 16 b Machine Will Not Shut 16 5 Control Board Check Proce gure 16 6 Control Board 17 DS VIN 17 Mos Es 17 yee cle Ee 17 DRAIN Re 17 oor ee end mr a etree ere 18 18 lll Technical 19 A Water Circuit and Refrigeration 2 19 B Wining eT UTILITIES 20 Timing 21 D Performance Data 23 IV Service Diagnosis Mp 24 10 Minute Diagnostic 444444 24 B Diagnostic sees T m 25 DN EET TOES 25 PGC SP POGGIO T T
30. e required refrigerant charge 10 Attach the expansion valve bulb to the suction line in the same location as the previous bulb The bulb should be at the 12 o clock position on the tube Be sure to secure the bulb with the clamp and holder and to insulate it 11 Place the new set of expansion valve covers in position 12 Replace the panels in their correct positions 13 Turn on the power supply F Removal and Replacement of Hot Gas Valve IMPORTANT 1 Always use a copper tube of the same diameter and length when replacing the hot gas lines otherwise the performance may be reduced 2 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 3 Always replace the strainer when replacing the hot gas valve 35 1 Turn off the power supply 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Recover the refrigerant and store it in an approved container 4 Remove the screw and the solenoid 5 6 Install the new valve Disconnect the hot gas valve using brazing equipment CAUTION 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 121 C 7 Install the new drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles
31. ect positions M Removal and Replacement of Spray Tubes 1 Turn off the power supply 2 Remove the outer panels and the evaporator insulation panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 4 5 6 Remove the spray tubes wa they were removed Remove the rubber hoses from the spray tubes water supply pipe Release the clamps and disconnect the rubber hoses Install the new spray tubes and replace the removed parts in the reverse order of which 7 Replace the evaporator insulation panels and the outer panels in their correct positions 8 Turn on the power supply N Removal and Replacement of Gear Motor 1 Turn off the power supply 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Disconnect the gear motor wiring harness from the back of the control box 4 Loosen the adjustment bolt then loosen the four bolts securing Gear Motor Bracket B 5 Slide Gear Motor Bracket B up to its highest position and retighten 6 Remove the chain 7 Loosen the socket set screw securing the sprocket then use a gear puller to remove the sprocket 8 Remove the bushing from the barrier and slide the gear motor wires free of the barrier Release the wires from the wire tie on the barrier 9 While supporting the gear motor and barrier remove
32. frigerant charge 12 Replace the removed parts in the reverse order of which they were removed 13 Replace the panels in their correct positions 14 Turn on the power supply 37 Removal and Replacement of Thermistor IMPORTANT 1 Fragile handle very carefully 2 Always use a recommended sealant High Thermal Conductive Type Model KE4560RTV manufactured by SHINETSU SILICONE Part Code 60Y000 11 or Part Code 4A0683 01 or equivalent 3 Always use a recommended foam insulation non absorbent type or equivalent 4 Do not shorten or cut the thermistor leads when installing it 1 Turn off the power supply 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel Thermistor Lead Cable Tie 3 Remove the control box cover AZ ZZ 4 Disconnect the thermistor leads from the K3 connector on the control board 5 Remove the plastic cable ties foam insulation thermistor holder and thermistor ce 6 Scrape away the old sealant on the thermistor holder and the suction pipe Foam insulation Thermistor Holder 7 Wipe off moisture or condensation on the suction pipe 8 Smoothly apply recommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the thermistor holder concave 9 Attach the new thermistor to the suction pipe in the same position as the previous thermistor Be very
33. fy that non bin control related issues are resolved 2 Dip switch no 7 should be in the ON position If the switch is in the OFF position the control board will not receive input from the bin control 3 Check to make sure no obstruction prevents the lever from moving to the bin full position 4 Push the lever in within the first 5 minutes of the freeze cycle If the machine does not shut off check the resistance values of the resistor wire harness You should read approximately 15 8 between the black terminal and the red terminal that connect to the K4 connector on the control board when the lever is in the bin full position proximity switch open If this reads approximately 7 9 KQ the resistors may be miswired or the proximity switch may be stuck closed Switch the black and white wires in the terminal housing or order a replacement wire harness If this does not resolve the problem replace the bin control assembly 5 Control Board Check Procedure Before replacing a control board that does not show a visible defect and that you suspect is bad always conduct the following check procedure This procedure will help you verify your diagnosis 1 Check the dip switch settings to assure that 3 4 7 8 9 amp 10 are in the factory default position Output test switch S3 should be OFF Switches 1 2 5 amp 6 are cleaning adjustments and the settings are flexible 2 Turn the control switch to ICE and check for proper control
34. hen the pump out timer stops counting the pump out is complete Pump out always occurs on the 2nd harvest after startup Then depending on the control board setting pump out occurs every cycle or every 2nd 5th or 10th cycle dip switch 5 amp 6 5 Normal Harvest Cycle LEDs 1 4 and 2 are on Comp continues to run HGV remains open and WV opens As the evaporator warms the thermistor reaches 48 F 9 C The control board then receives the thermistor s 3 9 signal and starts the harvest timer The water valve is open during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter When the harvest timer completes its count down the harvest cycle is complete and the next freeze cycle starts Note The unit continues to cycle through 3 4 and 5 sequence until the bin control is activated within first 5 minutes of freeze and shuts the unit down Legend Comp compressor DV Drain Valve FMS self contained fan motor F S float switch HGV hot gas valve PM pump motor SR Service Relay WV inlet water valve 7 1972M 9 UI AM BOIAJeS YS duind Nd se 10U ADH YOUMS 20 5 4 peurejuoo J es S A ALa urep AQ 1 4 5 pue sdois 10sseJduuoo uedo s 5 4 pezib1eue ep pezibueue dwog uedo 5 4 pezibieue
35. hould be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 23 IV Service Diagnosis A 10 Minute Diagnostic Procedure The 10 minute check out procedure is basically a sequence check which can be used at unit start up or for system diagnosis Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 70 F or warmer air and 50 F or warmer water temperatures Before conducting a 10 minute checkout check for correct installation proper voltage per unit nameplate and adequate water supply As you go through the procedure check to assure the components energize and de energize correctly If not those components and controls are suspect Check for voltage at the 10 pin connector Note that an activated bin control may have the machine off bin control will only shut down the machine within the first 5 minutes of the freeze cycle 1 Turn power OFF and access the control box 2 Turn power ON and place the control switch in ICE position A 5 second delay occurs 3 One Minute Fill Cycle The inlet water valve is energized After 1 minute the control board checks the float switch If the float switch is closed the unit cycles to harvest If closed continue to step 4 If the float switch is open the unit repeats the 1 minute fill cycle until water enters and the float swi
36. motor 4 Check for loose connection or open circuit and replace wiring as needed 5 Defective capacitor 5 Replace 6 Agitator rotates in 6 Check leads and reverse reverse direction the connections e Solenoid 1 Solenoid winding 1 Replace open 2 Wiring to solenoid 2 Check for loose connection or open circuit and replace wiring as needed 3 Overload due to 3 After tightening apply loosening screws thread sealant to the parts f Mechanism 1 Chain out of position 1 Place in position or or loose tighten 2 Apply o 3 Key of sprocket is not 3 Place in position in position 4 Bad alignment of 4 Readjust sprocket 5 Foreign matter 5 Remove foreign matter interrupting agitator g Ice Storage 1 No ice or little ice in 1 Make ice storage bin 2 Ice bridge or block 2 Break with a poker formed 2 Abnormal noise a Gear Motor or Gear 1 Bearing worn out 1 Replace Head 2 Grease leaks 2 Supply grease and replace O ring b Mechanism 1 Bad setting 1 Apply oil and readjust 2 Bad alignment of 2 Readjust sprocket 3 Foreign matter 3 Remove foreign matter interrupting agitator Solenoid 1 Overload due to 1 After tightening apply loosening screws thread sealant to the parts 2 Foreign matter on 2 Clean plunger 31 V Removal and Replacement of Components IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after the e
37. mpurities filter 29 Other Possible Cause 1 Icemaker will not stop a Bin Control See 1 4 Bin Control Troubleshooting when bin is filled with ice b Control Board 1 Defective 1 See 1 5 Control Board Check Procedure 2 Abnormal noise a Pump Motor 1 Bearings worn out 1 Replace b Fan Motor 1 Bearings worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade 3 Fan blade does not 3 Replace move freely c Compressor 1 Bearings worn out 1 Replace cylinder valve broken 2 Mounting pad out of 2 Reinstall position d Refrigerant Lines 1 Rub or touch other 1 Replace lines or surfaces 3 Ice in storage bin 1 Plugged often melts meme Bin 1 Drains not run the drain lines separately C Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin 2 Dispensing 1 No ice dispensed a Power Supply 3 Bad contacts 3 Check for continuity and replace recommended voltage b Fuse Inside Fused 1 Blown 1 Check for short circuit Disconnect if any and replace Dispense Switch 1 Connector from front 1 Connect panel not connected to control box 2 Bad contacts 2 Check for continuity and replace d Gear Motor 1 Thermal protector is 1 Allow to cool tripped 2 Gear motor winding 2 Replace opened 3 Bearing worn out 3 Replace 30 Problem Possible Cause 4 Wiring to gear
38. n power is supplied to the pump only This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator c WASH This model utilizes a solenoid operated cleaning bypass valve When the service switch is active and placed in the WASH position power is supplied to the pump and the cleaning valve This cleans both the inside and outside of the evaporator plate assembly Ill Technical Information A Water Circuit and Refrigeration Circuit 1 DKM 500BAH Spray Tube Condenser Valve High Pressure Evaporator Switch Heat Exchanger Strainer Switch Discharge Line Compressor Access Valve Expansion Valve Refrigerant Circuit Water Circuit 19 iagram D iring B W 1 DKM 500BAH OlSd LEFLZE YOUMS 55 5 0000 48 989 Di 046 iS AWA z0 ED 55394 lt lt NVC MON s N3IVM OK dtd e V ei l e Aet 48 Ug D 1 v 110 1 og TA p 10 t d WH LES lo HOLIMS S fo pings 72 MERT o 10010 So nga so 0 1 9o 6o Lolo A 0g Fo 9 s o 9 HOLINS MS OU WIW
39. nical Bin Control oz a 8 2 Microprocessor board revision level indicated by last 2 digits on label Connector K5 Float Switch Part Number Connector K1 Pins 1 through 10 1 9 Magnetic Contactor 2 Hot Gas Valve 3 Self Contained Fan Motor FMS 4 Pump Motor icemaking 5 Pump Motor drain 6 Water Valve 7 10 Power line bin control 8 Open ZEA ZEEE ST Switch for C board and ALPINE board service boards only Control Board 2A1410 01 factory 2A1410 02 service HOS 001A Control Products 10 Pin 10 2 Features a Maximum Water Supply Period 6 minutes Inlet water valve opening in the harvest cycle is limited by the harvest timer The water valve cannot remain open longer than the maximum period The water valve can close in less than six minutes if the harvest cycle is completed b Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if for two cycles in a row the harvest cycle takes more than 20 minutes to complete The control board will signal this problem using 2 beeps every 3 seconds The freeze timer shuts down the icemaker if for two cycles in a row the freeze cycle takes longer than the time specified to complete The control board will signal this problem using 3 beeps every 3 seconds The time is factory set using dip switches 9 amp 10 The reset button on the control board must be pressed with power on
40. nternal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice General Information A Construction 1 DKM 500BAH Mechanical Bin Control Circulating Valve Hot Gas Valve Spray Tubes Inlet Water Valve Drain Valve Expansion Water Supply Valve Inlet 7 Water Pump Float Switch Ice Cube Guide IP Agitator Shutter pepe cran Solenoid Assembly Dispense Switch Spout Extension Gear Motor Assembly Drier Dispense Switch Connector Condenser Strainer Front Panel Fan Motor Control Switches Compressor Control Box Drain Pan 6 Sequence of Operation The steps in the sequence are as outlined below When power is supplied a 5 second delay occurs at startup Note that the order of the LEDs from the outer edge of the board is 1 4 3 2 1 One Minute Fill Cycle LED 4 is on WV opens and the fill period begins After 1 minute the board checks for a closed F S If F S is closed the harvest cycle begins If not the unit will not start without adequate water in the sump This serves
41. on pipes using brazing equipment 6 Remove the hold down bolts washers and rubber grommets 7 Remove the compressor Unpack the new compressor package 8 Attach the rubber grommets of the prior compressor 9 Place the compressor in position and secure it using the bolts and washers 10 Remove the drier then place the new drier in position 11 Remove plugs from the suction discharge and process pipes 12 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 13 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 14 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 15 Connect the terminals and replace the terminal cover in its correct position 16 Replace the panels in their correct positions 17 Turn on the power supply D 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 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Recover the refrigerant and store it in an approved container 4 Remove the drier 5 Install the new drier with the arrow on the drier in the direction of the refrigerant flow Use nitrogen gas at a pressure of 3 to 4 P
42. orrect positions 7 Turn on the power supply 41 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 A Cleaning Instructions To clean the machine perform the cleaning and sanitizing procedures for the icemaker and bin in the order in which they appear below WARNING 1 Hoshizaki recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water conditions 2 To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners 3 Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin 1 Cleaning Procedure Icemaker 1 Dilute approximately 10 5 fl oz of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 2 gallons of warm water 2 Remove all ice from the evaporator and the bin Note To remove cubes on the evaporator turn off the power supply and turn it on after 3 minutes The defrost cycle starts and the cubes will be removed from the evaporator 3 Turn off the power supply 4 Remove the front panel and disconnect the connector from the control box 5 Move the control switch on the control box 2 to the SERVICE position Then move the service switch to the DRAIN position Bin 6 Repl
43. quipment is serviced IMPORTANT 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 Always install a new filter drier every time the sealed refrigeration system is opened Do not leave the system open for longer than 15 minutes when replacing or servicing parts A Service for Refrigerant Lines 1 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 the access valves and store it in an approved container Do not discharge the refrigerant into the atmosphere 2 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 4 Close the low side valve and high side valve on the service manifold 5 Disconnect the
44. r valve and hot gas valve de energize The unit is held in freeze by a 5 minute short cycle protection timer After 5 minutes the freeze cycle operation is transferred to the float switch for freeze termination During the first 5 minutes of freeze confirm that the evaporator temperature drops After 7 minutes in freeze remove the black float switch lead from the K5 connector The unit should immediately switch to the pump out cycle Diagnosis If the evaporator is not cold check to see if the hot gas valve is still open or if the expansion valve is not opening properly if the water valve is continuing to fill the reservoir if there are improper unit pressures or an inoperative compressor If the unit remains in freeze with the float switch removed replace the board Note Normal freeze cycle will last 20 to 40 minutes depending on model and 24 conditions Cycle times and pressures should follow performance data provided in this manual 6 Pump Out Cycle 10 20 second pump out the compressor remains energized the hot gas valve energizes the fan motor de energizes the pump motor stops for 2 seconds The service relay energizes restarting the pump motor and taking water from the sump and forcing it to go through the drain valve and down the drain for 10 20 seconds This removes contaminants from the water reservoir Check for clear tubing at the drain valve housing and check the unit drain for water flow Diagnosis If the pump
45. t Extension 6 Check for proper operation Maintenance Instructions 1 Exterior Panels To keep the exterior clean wipe occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt buildup 2 Air Filters The plastic mesh air filters located behind the louvers on either side of the unit remove dirt and dust from the air and keep the condenser from getting clogged As the filters get clogged the icemaker s performance will be reduced Check the filters at least twice a month When they are clogged use warm water and a neutral cleaner to wash the filters 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 the icemaker C Preparing the Icemaker for Long Storage IMPORTANT When shutting off the icemaker for an extended time drain the water tank and remove the ice from the bin The bin should be cleaned and dried Drain the icemaker to prevent damage to the water supply line at sub freezing temperatures using a foot or hand pump Shut off the icemaker until proper air temperature is resumed 1 Turn off the power supply 2 Remove the front panel and disconnect the connector from the control box 3 Move the control switch on the control box to the SERVICE position Then move the service switch to the DRAIN position 4 5 Replace the fron
46. t panel in its correct position Turn on the power supply for 2 minutes to allow the machine to drain Turn off the power supply Remove the front panel Move the control switch to the OFF position Close the water supply line shut off valve Remove ice from the bin then clean and dry the bin Reconnect the connector from the front panel to the control box and replace the front panel in its correct position IMPORTANT When the icemaker is not used for two or three days move only the control switch to the OFF position 45
47. tch closes low water safety protection during initial start up and at the end of each harvest Diagnosis If the water valve does not open check for no supply voltage at water valve terminals bad coil or plugged screen or external filter no water flow If unit fails to start harvest check for open float switch or bad 1 minute timer in board 4 Initial Harvest Cycle Inlet water valve remains energized contactor coil energizes to start the compressor and the hot gas valve energizes The evaporator warms and the thermistor senses 48 F 9 C The control board then receives the thermistor s 3 9 kO signal and turns operation of harvest over to the harvest timer The timer completes counting 1 to 3 minutes The unit then cycles to freeze Diagnosis Check if compressor is running hot gas valve is open water valve still open Average harvest cycle at factory setting is 2 to 3 minutes How long does initial harvest last 1 5 minutes after initial harvest begins touch the compressor discharge line Is it hot If not check refrigerant pressures and compressor operation If it is hot touch the inlet line to the evaporator Is it hot If it is hot and the freeze cycle is not starting check the harvest timer adjustment the thermistor for open circuit the discharge line temperature compressor efficiency and if the hot gas valve is fully open 5 Freeze Cycle Compressor remains energized pump motor and fan motor energize The inlet wate
48. tegrated circuits which are susceptible to failure due to static discharge It is especially important to touch the metal part of the unit when handling or replacing the board Do not touch the electronic devices on the board or the back of the board to prevent damage to the board Do not change wiring and connections Do not misconnect K3 K4 and K5 because the same connector is used for the thermistor float switch and mechanical bin control Always replace the whole board assembly if it goes bad Do not short out power supply to test for voltage Alarm Reset Switch Backup Freeze Timer LED Backup Harvest Timer LED Alarm Buzzer Power LED lights when power is supplied to the board Relay LEDs 4 indicate which relays are energized as listed below LED 2 Hot Gas Valve HGV Self Contained Fan Motor FMS FMS off when LED on LED 3 Pump Motor PM on at pump out only LED 4 Water Valve WV LED 1 Compressor Comp Transformer Connector Control Board Layout Control Products E Control Board Output Test Switch used to test relays on board Dip Switch 0008810 OUTPUT TEST a e mooo Yo RI o 600000 a ea a RO Ru 555669959 z die 5 08 a onnector m v 2 RX 0 006070 9 gai Harvest Control amp alte 0 thermistor ue z 27 4 Mecha
49. ter 2 Make sure that the power supply is off 3 Remove the grill and chute from the front panel 4 Remove the shutter and spout extension as follows a Remove the snap pin fitted to the shutter shaft Shift the shaft to the left pull out the right side and slide out b Remove the four thumbscrews securing the spout extension and remove the spout extension 5 Remove the two thumbscrews securing the bin control assembly to the bin cover Note the orientation of the stainless steel bracket then remove the bin control and bracket from the bin cover Carefully remove the bin control paddle from the bin control body 6 Scrub the inside of the bin the agitator the bin spout the spout extension the shutter the front panel spout the grill the chute the bin cover and the bin control assembly using a nylon scouring pad brushes and cleaning solution 7 Rinse all parts thoroughly with clean water then proceed to 4 Sanitizing Procedure Bin Bin Control Connector 4 Sanitizing Procedure Bin DE E 1 Dilute approximately 5 fl oz of a 5 25 sodium hypochlorite solution chlorine bleach with 1 gallon of warm water Cover 2 Wash all parts from step 6 of Cleaning Procedure Bin with the sanitizing solution 3 Rinse all parts thoroughly with clean water 4 Reassemble all parts in the reverse order of the removal procedure Bin Spout 5 Turn on the power supply Spou
50. the four bolts securing them to Gear Motor Bracket B Carefully remove the motor and barrier Chain Bolts 3 Lower sprocket takes 2 5 mm Gear Motor allen wrench Bracket B Sprocket Bushing Pd UN b b gt Ec A Gear Motor Ld Barrier Gear Motor Bracket B Sprocket Bolt 10 Install the new gear motor assembling the removed parts in the reverse order of the above procedure Note When weight 2 2 Ib is applied to the chain at the center the displacement must be 0 31 to 0 51 Lubricant Class SAE 20 must be applied to the chain using a cloth 11 Replace the panels in their correct positions 12 Turn on the power supply O Removal and Replacement of Dispense Switch 1 Turn off the power supply 2 Remove the front panel Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Remove the dispense switch assembly 4 5 6 Turn on the power supply Install a new dispense switch Replace the front panel in its correct position P Removal and Replacement of Solenoid 1 Turn off the power supply 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Disconnect the connectors from the solenoid leads 4 Remove the solenoid and install a new solenoid 5 Connect the connectors to the solenoid leads 6 Replace the panels in their c
51. to reset either of these safeties c High Temperature Safety The temperature of the suction line in the refrigeration circuit is limited by the high temperature safety This protects the unit from excessively high temperatures If the evaporator temperature rises above 127 7 F 53 4 C the thermistor operates the safety This shuts down the circuit and the icemaker automatically stops The control board will signal this problem using 1 beep every 3 seconds The reset button on the control board must be pressed with power on to reset the safety d Low Water Safety The control board checks the position of the float switch at the end of the initial one minute water fill cycle and at the end of each harvest cycle If the float switch is in the up position electrical circuit closed the control board changes to the ice making cycle If the float switch is in the down position electrical circuit open the control board changes to additional one minute water fill cycles until water enters the sump and the float switch closes When the float switch closes the control board changes to the ice making cycle The unit will not start without adequate water in the sump This serves as a low water safety to protect the water pump e High Voltage and Low Voltage Cut outs The maximum and minimum allowable supply voltages of this icemaker are limited by the high voltage and low voltage cut outs If miswiring especially on single phase 3 wire models c
52. tor Temp temperature gt 127 F 53 C Harvest Backup Timer harvest gt 20 min for two cycles in a row Freeze Timer freeze gt specified setting for two cycles in a row Timer is factory set using dip switches 9 amp 10 Short Circuit between the K4 connec tion on the control board and the bin control Open Circuit between the K4 connec tion on the control board and the bin control Check for harvest problem stuck HGV or relay hot water entering unit or shorted thermistor Orange LED marked H TIMER lights up Check for open thermistor HGV not opening TXV leaking by low charge or inefficient compressor Yellow LED marked F TIMER lights up Check for F S stuck closed up WV leaking by HGV leaking by TXV not feeding properly low charge or inefficient compressor Resistor wire harness shorted Check and replace wire harness if necessary Resistor wire harness circuit open or control board open Check and replace component if necessary To manually reset the above safeties press the alarm reset button with the power supply on No of Beeps every 3 sec Type of Alarm Low Voltage Red LED will turn off if voltage protection 92Vac 5 or less operates 7 High Voltage The control voltage safeties automatically mM 147Vac 5 or more reset when voltage is corrected Legend Comp compressor DV Drain Valve FMS self contained fan motor F S float switch HGV hot gas valve PM p
53. ump motor SR Service Relay thermostatic expansion valve WV inlet water valve 3 Controls and Adjustments a Default Dip Switch Settings The dip switch is factory adjusted to the following positions DpSweNo 1 2 3 4 5 7 s s Freeze Timer 9 amp 10 Normally in the OFF position Mechanical Bin Control Pump Out Frequency Control 5 amp 6 Pump Out Timer 3 amp 4 Harvest Timer 1 amp 2 b Harvest Control Thermistor A thermistor semiconductor is used for a harvest control sensor The resistance varies depending on the suction line temperatures The thermistor detects the temperature of the evaporator outlet to start the harvest timer No adjustment is required If necessary check for resistance between thermistor leads and visually check the thermistor mounting located on the suction line next to the evaporator outlet Temperature F Temperature C Resistance 0 a 14401 10 613 832 0 600 90 832 1633 13 Check a thermistor for resistance by using the following procedure 1 Disconnect the connector K3 on the board 2 Remove the thermistor See V H Removal and Replacement of Thermistor 3 Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes 4 Verify the temperature of the glass then check for resistance between thermistor leads See the table above for temperature and resistance v
54. voltage If the red LED is ON the control voltage is good If the red LED is OFF check the control transformer circuit 16 3 Check the 115 volt input at the 10 connector Check the brown wire at pin 10 toa white neutral wire for 115 volts Always choose a white neutral wire to establish a good neutral connection when checking voltages A jumper also feeds 115 volts into pin 7 If no voltage is present check the 115 volt supply circuit 4 The output test switch S3 provides a relay sequence test With the control switch in the OFF position place S3 ON and then move the control switch to the ICE position The correct lighting sequence should be none 2 3 4 1 and 4 normal sequence every 5 seconds Components e g the compressor will cycle during the test Note that the order of the relays from the outer edge of the board is 1 4 3 2 Note If the LEDs light in a different sequence or the 5 second interval does not occur the control board is bad and should be replaced 5 After checking the sequence place S3 back in the OFF position The S3 switch must remain in the OFF position during normal operation This completes the output test and the unit is now in the 1 minute fill cycle 6 Control Board Replacement The application switch located between relay X3 amp X4 must be set to match the original board application Place this switch in the ALP position if there is no white wire supplied to the K1 connector If there is
55. witch connector from the control box when removing the front panel 4 Loosen the fitting nut Be careful not to lose the washer 5 Remove the screws securing the valve to the bracket 6 Remove the screws attaching the bracket to the machine wall then remove the bracket from the unit 7 Remove the valve outlet tubing by releasing the clamp 8 Disconnect the terminals from the water valve 9 Install the new water valve and replace the removed parts in the reverse order of which they were removed Make sure the washer is in place in the fitting nut 10 Open the water supply line shut off valve 11 Turn on the power supply 12 Check for leaks 13 Replace the panels in their correct positions L Removal and Replacement of Pump Motor 1 Turn off the power supply 2 Remove the panels Be sure to disconnect the dispense switch connector from the control box when removing the front panel 3 Remove the three screws securing the float switch assembly then remove the assembly 4 Remove the two screws securing the barrier directly over the pump then remove the barrier 5 Remove the wiring connectors from the pump motor leads 6 Remove the four screws securing the pump motor disconnect the hoses then remove the pump motor 39 7 Install the new pump and replace the removed parts in the reverse order of which they were removed 8 Turn on the power supply and check for leaks 9 Replace the panels in their corr
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