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Hoshizaki 300BAH(-OS) User's Manual

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2. LBU BR NOISE K LLER VAAN BK DBU LBU DISPENSE MODE SWITCH praf CONTROL SWITCH R OM NO i EEE 9 L kg 2 co RD Ki 2343 6 1 2345 6 9 BK il w WATER DISPENSE R SENSOR war 2047 3 W BK W W BU i BR wo r m Win N PORTIO RELAY BIN CONTROL SWITCH LBU BR 19 High Pressure Switch 41242 PSIG 327421 PSIG DA IR LIGHT BLUE ORANGE PIN ITE RED C Performance Data 1 DCM 300BAH OS APPROXIMATE ICE PRODUCTION PER 24 HR bs day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR gal day I day HEAD PRESSURE PSIG kg cm G SUCTION PRESSURE PSIG kg cm G Water Temp F Temp F ae ee 0 Se a aes te 90 237 107 232 181 70 653 654 80 656 658 1 10 ae ae 1 1 al 4 aa 200 14 1 20
3. position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 3 Remove the front cover of the storage bin Remove spout B then remove spout A See Fig 2 4 Remove the apron panel then remove the left side panel 5 Remove the evaporator bracket 6 Remove the bolts securing the lower housing to the gear motor Lift the evaporator up slightly 7 Remove the 3 gear motor bolts 8 Disconnect the wiring from the gear motor then remove the gear motor 9 Remove the spline coupling from the old gear motor and attach to the new gear motor 10 11 12 Connect the gear motor wires 13 14 15 Replace spout A spout B and the front cover of the storage bin in their correct positions Place the new gear motor in the drain pan Secure the gear motor Lower the evaporator down and secure it to the gear motor Replace the evaporator bracket in its correct position 16 Move the power switch to the ON position then replace the panels in their correct positions 17 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 46 7 Dispense Auger and Agitator 1 Move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 2 Remove the front cover of the storage bin 3 Remove the thu
4. 42 9 Move the power switch to the ON position then replace the panels in their correct positions 10 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 3 Removal and Replacement of Auger 1 Move the control svvitch to the DRAIN position and drain all of the vvater from the evaporator 2 After the water has stopped draining move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 3 Remove the front cover of the storage bin Remove spout B then remove spout A See Fig 2 4 Remove the apron panel then remove the left side panel 5 Remove the allen head cap screws securing the extruding head Using the cutter lift out the auger assembly 6 Remove the cutter extruding head and upper part of the mechanical seal from the auger and place them on the new auger NOTICE To help prevent water leaks be careful not to damage the surfaces of the O ring or mechanical seal 7 Install the new auger assembly with the upper part of the mechanical seal attached and tighten down the allen head cap screws 8 Replace spout A spout B and the front cover of the storage bin in their correct positions 9 Move the power switch to the ON position then replace the panels in their correct positions 10 Turn on the power supply then move the control switch to
5. 9 Turn on the power supply then move the 2 control svvitch to the ICE position to start 7 T the automatic icemaking process s x Dispense Motor Dispense Auger Fig 4 47 VI Cleaning and Maintenance This icemaker must be cleaned and maintained in accordance with the instruction manual and labels provided with the icemaker Consult with your local distributor about cleaning and maintenance service To obtain the name and phone number of your local distributor visit www hoshizaki com or call Hoshizaki Technical Support at 1 800 233 1940 in the USA A WARNING e Only qualified service technicians should service this icemaker e CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after any cleaning or maintenance is done to the icemaker Make sure that none have fallen into the dispenser unit storage bin e The storage bin is for ice use only Do not store anything else in the storage bin Bin Control Assembly gt gt Agitator Float Switch Assembly Evaporator Assembiy Dispense Auger Agitating Motor Dispense Motor OFF DISPENSE MODE A PORTION Spout Cover DRAIN W CONTINUOUS Safety Switch Optical Sensors OS model Fig 5 48 A Cleaning and Sanitizing Instructions Hoshizaki recommends cleaning and sanitizing this icemaker at least twice a year More frequent cleaning and sanitizing however may
6. NOTE To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number e Complete and detailed explanation of the problem IMPORTANT This manual should be read carefully before the icemaker is serviced Read the warnings and guidelines contained in this booklet carefully as they provide essential information for the continued safe use service and maintenance of the icemaker Retain this booklet for any further reference that may be necessary CONTENTS Important Safety MON DIV AMON abad 5 l Specification S ana ROSE WOZEK WORA ERAN NAN br bb SAN NANA 7 Ar TGB uda OGN AE ADA bala a ao aaa OR AK 7 iL General IMPOKMANOM a br a 8 A CONSCI Meersen e ea a EE aN e EEC eo EE ee EEEE EAEE E ETEN 8 1 ene AT 8 2 CEMAKING RET ea 9 B Sequence OT OPClalO BL baa a ayama aka b d k 10 1 Sequence Cycles and Shutdown sse cia eee azab aaa La duma aaa nn rna non 10 a FIINCYCIE NE PGE PA E K 10 b Ce Purge Cyce aoc Aha Oda R ao 10 Freeze Cycle may d Osa m B ama ama zed ea 10 d Dilin o 10 SUC OWN o a c A KOPE E aA to NE aaa 10 2 SSUSNCE Fiew Cha alabal q aaa aaa ar ONEEN 11 C Control BONG iesirea senas rne RN NR a aba enn RN aa 12 Control Board Layout assine an aaa RE aN ia 13 a DOM 30
7. be required in some existing water conditions A WARNING e To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners e Carefully follow any instructions provided with the bottles of cleaning and sanitizing solution e Always wear liquid proof gloves and goggles to prevent the cleaning and sanitizing solutions from coming into contact with skin or eyes e After cleaning and sanitizing do not use ice made from the cleaning and sanitizing solutions Be careful not to leave any solution on the parts or in the dispenser unit storage bin 1 Water System a Cleaning Solution Dilute 9 6 fl oz 0 29 1 of Hoshizaki Scale Away with 1 6 gal 6 0 1 of warm water b Cleaning Procedure 1 Close the icemaker water supply line shut off valve 2 Move the control switch to the DRAIN position See Fig 5 Allow the water system to drain for 5 minutes 3 Move the dispense mode switch to the CONTINUOUS position then dispense all of the ice from the storage bin Note Ice dispenses continuously for a maximum of 60 seconds per activation 4 Move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 5 Remove the storage bin cover Remove spout B then remove spout A 6 Pour the cleaning solution over the extruding head until the evaporator assembly and the reservoir are full and the solut
8. energizes Diagnosis If reservoir is empty and WV is off confirm LF S status See IV E Float Switch Check and Cleaning Check that WV energizes and water fills the reservoir If not check that the water supply line shut off valve is open possible clogged water filters and clogged WV screen If LF S is open and WV is off check for 24VAC at CB K2 connector pin 7 R wire to CB K2 connector pin 8 LBU wire If 24VAC is not present and the 24VAC 1A fuse is good replace CT If 24VAC is present check for 24VAC at K3 connector pin 3 DBU wire to a neutral LBU wire If 24VAC is not present replace CB If 24VAC is present check for 24VAC at the control switch R wire to a neutral LBU wire If 24VAC is not present make sure the control switch is in the ICE position Replace the control switch if defective If 24VAC is present check for 24VAC at WCR terminal 1 BR wire to WCR terminal 5 R wire If 24VAC is present WCR is energized or defective If energized check that UF S is open See IV E Float Switch Check and Cleaning If not energized replace WCR If 24VAC is not present check WCR terminal 1 BR wire to a neutral LBU wire If 24VAC is present check WV solenoid wire connections and continuity If WV is energized and refill exceeds FT with no water in the reservoir check for DV leaking If reservoir is full and overflowing check for open UF S See IV E Float Switch Check and Cleaning If UF S is closed check that WCR
9. energizes de energizing WV If not check for 24VAC at WCR terminal 7 BK wire to WCR terminal 8 LBU wire If 24VAC is present and WV does not de energize replace WCR If WV de energizes and water continues to fill the reservoir replace WV 22 9 Ice Purge Cycle GM LED is on GM and GMPR energize 60 sec ice purge timer starts GM runs for 60 sec to clear any ice from the evaporator Note GM cannot energize unless UF S is closed WCR is energized and WCR terminals 4 O wire and 6 GY wire are closed Diagnosis If GM LED is off check control switch and BC continuity If either are open CB GM LED will not turn on If both are closed and CB GM LED does not turn on replace CB If GM LED turns on and GM does not energize check for 115VAC at CB K1 connector NO pin DBU wire to a neutral W wire If 115VAC is not present replace CB If 115VAC is present check GM external protector overload GM windings continuity and GM capacitor If GM external protector or GM internal protector is open allow to cool and reset If reset does not occur replace as needed If GM winding is open replace GM If GM energizes but auger does not turn check coupling between auger and GM If Comp energizes at the same time GM energizes check CB See IV C Control Board Check 10 Freeze Cycle COMP and GM LEDs are on 60 sec ice purge timer terminates GM continues CB confirms GM operation through GMPR terminal 3 BR wire
10. help you verify your diagnosis Before proceeding check for proper voltage per unit nameplate Check that the 24VAC 1A fuse 10 5VAC 0 5A CT fuse are good and the 115VAC GM external protector is not tripped When checking high voltage 115VAC always choose a neutral W wire to establish a good neutral connection When checking low voltage 24VAC and 10 5VAC always choose a neutral LBU wire from CT to establish a good neutral connection WARNING LBU wires are used in both high voltage and low voltage applications When checking low voltage 24VAC and 10 5VAC confirm that the neutral LBU wire being used is the CB K4 connector pin 2 LBU wire from the CT Not the LBU wire used for GM operation 115VAC or DV 24VAC power supply operation When checking CB DC voltage 5VDC use CB K3 connector pin 1 for DC ground GND The POWER LED remains on unless power supply is interrupted IMPORTANT lcemaker will not start unless the front panel safety switch is engaged 1 Remove the front panel and control box cover 2 Turn on the power supply Move the power switch to the ON position 3 Startup POWER LED on Move the control switch to the ICE position Engage the safety switch the POWER LED turns on IMPORTANT CB POWER LED will not come on unless the front panel safety switch is engaged Diagnosis If POWER LED does not turn on check for 10 5VAC at CB K4 connector pin 1 BR wire to pin 2 LBU wire If 10 5VAC is pres
11. of the control switch Replace the control switch if defective If 24VAC is not present GMPR is energized or defective If 24VAC is present check for 24VAC at GMPR terminal 2 P wire to a neutral LBU wire If 24VAC is not present check GMPR continuity between terminals 2 P wire and 6 LBU wire If open replace GMPR Next check for 24VAC at DV If 24VAC is present and DV does not energize check DV solenoid continuity b2 Manual Drain 150 sec shutdown sequence bypass To bypass the 150 sec shutdown sequence remove the front panel then move the power switch to the OFF position Next move the control switch to the DRAIN position then move the power switch to the ON position DV energizes IMPORTANT Drain valve will not energize unless the front panel safety switch is engaged Diagnosis If DV does not energize check for 24VAC at CB K3 connector pin 3 DBU wire to a neutral LBU wire If 24VAC is not present confirm 24VAC power supply to CB K2 connector pin 7 R wire on push button model and pin 9 R wire on Opti Serve model to a neutral LBU wire If 24VAC is present at CB K2 pin 7 push button model or pin 9 Opti Serve model and not on CB K3 connector pin 3 DBU wire replace CB If 24VAC is present at CB K3 connector pin 3 DBU wire check for 24VAC at control switch LBU wire to a neutral LBU wire If 24VAC is not present check continuity of the control switch Replace the control switch 24 if defect
12. panels in their correct positions 21 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 44 5 Removal and Replacement of Mechanical Seal and Lovver Housing 5a Mechanical Seal 1 Move the control switch to the DRAIN position and drain all of the water from the evaporator 2 After the water has stopped draining move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 3 Remove the front cover of the storage bin Remove spout B then remove spout A See Fig 2 4 Remove the apron panel then remove the left side panel 5 Remove the extruding head heater and the allen head cap screws securing the extruding head 6 Using the cutter lift out the auger assembly then remove the evaporator bracket 7 The mechanical seal consists of two parts One moves along with the auger and the other is fixed on the lower housing NOTICE If the contact surfaces of these two parts are worn cracked or scratched the mechanical seal may cause water leaks and should be replaced 8 Remove the allen head cap screws securing the evaporator to the lower housing 9 Raise the evaporator up to access the lower housing 10 Remove the mechanical seal from the housing If only replacing the mechanical seal proceed to step 13 NOTICE To help prevent water leaks be carefu
13. storage bin cover using a neutral cleaner Rinse thoroughly after cleaning Replace the storage bin cover and the front panel in their correct positions 54 VII Disposal This icemaker contains refrigerant and must be disposed of in accordance vvith applicable national state and local codes and regulations Refrigerant must be recovered by properly certified service personnel 55
14. the ICE position to start the automatic icemaking process 4 Removal and Replacement of Evaporator NOTICE e 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 Install the new drier with the arrow on the drier in the direction of the refrigerant flow e When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 1 Move the control switch to the DRAIN position and drain all of the water from the evaporator 2 After the water has stopped draining move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 43 3 Remove the apron panel then remove the left side panel 4 Recover the refrigerant and store it in an approved container 5 Remove the front cover of the storage bin Remove spout B then remove spout A See Fig 2 6 Remove the allen head cap screvvs securing the extruding head Using the cutter lift out the auger assembiy 7 Remove the evaporator bracket and disconnect the vvater hoses 8 Disconnect the inlet and outlet tubing 9 Remove the allen head cap screws securing the evaporator to the lower housing 10 11 Inspect the mechanical seal and O ring prior to installing the new evaporator The mech
15. using the steps in IV C Control Board Check 1 No Ice Production Startup 1 Power Supply 2 Water Supply External water filters clogged 3 Power Switch 4 Safety Switch 5 Power Protect Relay 6 Control Transformer a Coil winding open or shorted 115VAC 24VAC and 10 5VAC 7 1A Fuse 24VAC Control Board 8 5A Fuse 10 5VAC Control a Blown Board 9 Control Board a Defective See IV C Control Board Check 10 Control Switch T Bin Control 12 High Pressure Switch i Water Control Relay 2 niet Water Valve ee 3 Float Switch See IV E Float Switch Check Defective and Cleaning TID 0 TID o o a b C 22 2 34 Ice Purge Cycle 1 Control Board No power to gear motor 2 Gear Motor 2 External protector gear motor overload open Internal protector open Motor winding open Mechanical failure 3 Coupling Defective 1 Control Board 2 Compressor Capacitor defective 3 Fan Motor 4 Evaporator 5 Thermostatic Expansion Valve R miocim o jajo jojo Operating erratically 6 Refrigerant Charge Low 7 Drain Valve Dirty leaking by Defective coil 8 Water System a Water leaks EENE 2 Float Switch a Float does not move freely See IV E Float Switch Check b Defective and Cleaning 3 Water Control Relay Energized upper float switch stuck closed Defecti
16. 0 14 1 237 n a ag 37 ze iv z _80 39 27 39 27 39 27 go m 29 m 29 m 29 100 45 32 45 32 45 32 105 87 mz zi s wo se 145 138 qat 33 124 at 118 112 20 tto ar i 24 a z3 KRONE HEY HE lt a 5 z 9 2 28 5 25 100 25 25 4 25 m 141 200 141 200 90 2 o TOTAL HEAT OF REJECTION 3 500 BTU h AT 90 F WT 70 F Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 20 IV Service Diagnosis A WARNING e This icemaker should be diagnosed and repaired only by qualified service personnel to reduce the risk of death electric shock serious injury or fire e Risk of electric shock Use extreme caution and exercise safe electrical practices e Moving parts e g fan blade can crush and cut Keep hands clear e CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after the icemaker is serviced Make sure that none have fallen into the storage bin e Make sure all food zones in the icemaker and storage bin are clean after the icemaker is serviced For cleaning procedures see VI Cleaning and Maintenance A Ice Production Check To check production prepare a bucket or p
17. 0 Ibs POTABLE WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN ICE MAKING SYSTEM HARVESTING SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION GEAR MOTOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED OPTIONAL OPERATING CONDITIONS 115 120 60 1 115 V 6 0 RLA 29 LRA 120 V 1 45 FLA 80 W 115 V 0 8 FLA 16 W 115 V 0 9 FLA 55 W 115 V 0 9 FLA 55 W 120 V 0 2 A 20A 20 A 20 A WATER TEMP F P 500 70 90 321 146 307 139 291 132 100 Cubelet Compressed Flake Ice 88 90 70 F Conductivity 200 uS cm 40 Ibs 90 70 F 70 50 F 661 6 84 653 4 88 29 12 5 40 12 5 26 x22 1 2 x40 661x571x1016 Stainless Steel Galvanized Steel Rear Net 215 Ibs 98 kg Shipping 240 Ibs 109 kg Permanent Connection Inlet 1 2 FPT Drain Pan 3 4 FPT Bin Drain 3 4 FPT Auger Type Direct Driven Auger 80 W Gear Motor Float Switch N A Mechanical Bin Control Proximity Switch Hermetic Model ASE24C3E IAA 257 Air Cooled Fin and Tube Type Copper Tube on Cylinder Thermostatic Expansion Valve R 404A 15 9 oz 450 g High 460 PSIG Low 290 PSIG High Voltage Cut Out Internal Auto Reset External Prote
18. 0BA a ba a Eba as nan 13 B DEM 300BAH 0 S LA AD b l 14 LED Lights and COMBO ENIS aso Go w mama adam ar a a apa basmaz 15 D Power Switch Control Switch and Dispense Mode Switch 15 N Seu e wew ama maa OWO EOKA ROE NEN EEEn 15 aaa TAI TR a E E Se De MHR SRA 16 EDA TT 16 BYORAI o R z icant aka axsa m kan RAR asa ma 16 s Dispense Mod SWC L l m n m y a a NNE ed Oj 16 a CONTINUOUS aan ala au aba ada aa OG 16 d l adam ma s b sasa da al 16 Vl Tocbnicaliltormallonuuy l l a R Da ays a ya b asa zala 17 A Water Circuit and Refrigeration Circuit eee 17 B Wining ladan isione balal bala laz lala adana 18 1 D CM 300B AT b di 18 2 UUM B LE 19 ap basa 20 IV Service Diagnosis 0 00 21 A Ice FroduotonEnesku zo va EEE AR ay 21 B Diagnostic Procedure KA KLA 21 C Control Board CCK 00 90000 7 RR rr nn nn 26 D Bin Control Chek Z PE CAE ay 31 E Float Switch Check and Cleaning esse eee eee 32 1 Float Switch 32 2 Float Switch Cleanind dala
19. 12 hr timer DV drain valve DVT drain valve timer 20 min timer FM fan motor timer 90 sec low water safety GM gear motor GMPR gear motor protect relay LF S lower float switch UF S upper float switch WCR water control relay VVV inlet water valve 10 01504 NO 94 0 Yoeq YIUMS y UB UOHISO NIVHO 24 U UIUMS 101002 su eoejd uonsod 440 94 0 U HMS Jamod y SAOW adUaNbaes UMOPINUS 2 s 0G 94 SSEdAQ OJ 8J0N HEMS M 9 UMOPINYS s eulul u nb s UMOpINUS 98S 0G v hun 21 JOU s op A EA UlEJp y f azaa su Buunp uonmsod AN YHG 24 o BuluoliMS USU Alquasse 1ojelodene pue 4OAH S L BU WOJ UIEJP O JezIIUeS DUR SMO IE 914 ayewa y BulzilluEs pue Bulueejo usyMm p sn SI YMS 104002 y UO UONISOd NIYHG SUL UORISOd NIVHG 24 U 51 YUIUMS 04140 ay U8UM pozibleuj sjuduoduwog SABA J8 UI AM UDHMS eo 1eddn S 4N YOUMS TEO 18MO S 4 Jojow 1806 IND G lin Ajapes MOJ 985 06 29W 4 14 JO OW UEJ INH G lin uIw 0Z 18H UIEJP L Q UIEJP Ad USD 20 21 Jewq BA ureJp LDQ Josseidwoo dwiog pueog 0114000 42 lonuoo 10 28 puabay seziBieue 8p WD sanunuoa AM s solo 9 4 Inun sanunuoa AM 2 Sequence Flow Chart peziBieue ep dwog lt s 09 25000 2 S 06 UNLUIXEJN u nb s umopynys 1 jeu SHE S 9 9A9
20. A RR RER nr rna nen 51 b Sanitizing olun aa Bala 51 c Cleaning and Sanitizing 51 ELL as aie a s ba n 53 C Preparing the Icemaker for Periods of Non Use s iii een aaa ner rr nanna 54 YIL m m ben 55 important Safety Information Throughout this manual notices appear to bring your attention to situations which could result in death serious injury damage to the appliance or damage to property A WARNING Indicates a hazardous situation which could result in death or serious injury NOTICE Indicates a situation which could result in damage to the appliance or property IMPORTANT Indicates important information about the use and care of the appliance A WARNING This icemaker should be destined only to the use for which it has been expressly conceived Any other use should be considered improper and therefore dangerous The manufacturer cannot be held responsible for injury or damage resulting from improper incorrect and unreasonable use Failure to service and maintain the appliance in accordance with this manual will adversely affect safety performance component life and warranty coverage and may result in costly water damage To reduce the risk of death electric shock serious injury or fire follow basic precautions including the following e Only qualified service technicians should install and service this icemaker e To
21. AC is not present replace CB If 24VAC is present check for 24VAC at GMPR terminal 2 P wire to a neutral LBU wire If 24VAC is not present GMPR is energized or defective If GMPR is energized confirm GM is off If not DCT has not terminated or 60 sec shutdown sequence is not complete If 60 sec shutdown is complete and GM is still energized replace CB If 24VAC is present check for 24VAC on DV If 24VAC is present and DV does not energize check DV solenoid continuity b1 Manual Drain 150 sec shutdown sequence Move the control switch to the DRAIN position The 150 sec shutdown sequence starts 90 sec after moving the control switch to the DRAIN position Comp and FM de energize 60 sec later GM de energizes and DV energizes DV continues until the control switch is moved to the OFF or ICE position or power is turned off Diagnosis Once GM de energizes DV energizes If not check for 24VAC at CB K3 connector pin 3 DBU wire to a neutral LBU wire If 24VAC is not present confirm 24VAC power supply to CB K2 connector pin 7 R wire on push button model and pin 9 R wire on Opti Serve model to a neutral LBU wire If 24VAC is present on CB K2 pin 7 push button model or pin 9 Opti Serve model and not on CB K3 connector pin 3 DBU wire replace CB If 24VAC is present at CB K3 connector pin 3 DBU wire check for 24VAC at control switch LBU wire to a neutral LBU wire If 24VAC is not present check continuity
22. BU wire to a neutral LBU wire with the Opti Serve sensor engaged If 24VAC is not present replace CB If 24VAC is present and no water is dispensed check for water supply line shut off valve closed clogged water filters clogged WV screen If the water supply is good replace DispWV Control Board Connector Control Board DC Ground Disengaged Engaged K5 Pin 7 R wire OVDC OVDC K5 Pin 8 W wire To K3 Pin 1 open 5VDC OVDC K5 Pin 9 BK wire 5VDC 5VDC 5 Fill Cycle CB directs 24VAC power supply to WV from CB K2 connector pin 7 R wire to CB K3 connector pin 3 DBU wire Confirm 24VAC between CB K2 connector pin 7 R wire and pin 8 LBU wire Next confirm 24VAC between CB K3 connector pin 3 DBU wire and CB K2 connector pin 8 LBU wire If 24VAC is present between CB K2 connector pin 7 R wire and 8 LBU wire but not between CB K3 connector pin 3 DBU wire and CB K2 connector pin 8 LBU wire replace CB If 24VAC is present between CB K3 connector pin 3 DBU wire and CB K2 connector pin 8 LBU wire and fill cycle does not start see IV B 8 Fill Cycle 6 Ice Purge Cycle GM LED is on UF S closes WCR relay terminal 6 LBU wire and 4 O wire close CB K1 connector COM BR wire and CB K1 connector NO DBU wire contacts close energizing GM and GMPR 60 sec ice purge timer starts Check for 115VAC at CB K1 connector NO DBU wire to a neutral W wire If 115VAC is not present confirm conti
23. CONTROL 3 Dispense Mode Switch The dispense mode switch has 2 positions CONTINUOUS and PORTION a CONTINUOUS When the dispense mode switch is in the CONTINUOUS position ice dispenses continuously for a maximum of 60 seconds per activation b PORTION When the dispense mode switch is in the PORTION position ice dispenses for the amount of time determined by the ice dispense time setting DISPENSE MODE A PORTION WY CONTINUOUS The ice dispense time control is located on the control board The dial indicates dispense time in seconds and is adjustable between 0 6 and 20 seconds When shipped the ice dispense time control is set to the minimum dispense time of 0 6 sec approximately 0 72 oz Ice Dispense Time Control 6 6 15 57 oz 2 6 D SP T ME 20 xi 87 6 54 3 2 16 III Technical Information A VVater Circuit and Refrigeration Circuit Inlet Spout Water Valve Water Supply IS Float Svvitch dum VVater Level Reservoir Overflow Gear Motor Fan Motor Condenser High Pressure Switch q r Access Valve Refrigeration Circuit uu Water Circuit 17 Expansion Valve IS Drain Valve IS Dispense VVater Valve Compressor To Drain Access Valve B VViring Diagrams OL
24. ET WHITE V EXTERNAL PROTECTOR LBU LBU LBU BR Y YELLOW BR LBU INTERNAL PROTECT DBU 0 480 POWER SWITCH R BK GH T li ICH POWER PROTECT RELAY ge reg RACE BK DBU BR 0 LBU BK R R NOISE KILLER gr Ad LBU pran CONTRO DBU x ICE BR ctw No 2345618 3 ie 0 6 SE KILLER BR dr BK x DCM PB CONTROL BOARD R BU Ki DBU NOISE KILLER Ta ak R KE oe d lg WATER CONTROL RELAY GY p u DRAIN y LOF 9 CONTROLSWITCH ICE G LBU LBU 4 18 2 DCM 300BAH OS LBU INTERNAL PROTECTOR LBU INTERNAL PROTECTOR LBU BR POWER SWITCH A R BK SAFETY SWITCH 4 BK LBU
25. Hoshizaki America nc Cubelet cemaker Dispenser Models DCM 300BAH OS SERVICE MANUAL A Superior Degree of Reliability vvvvvv hoshizaki com Number 73189 ssued 1 5 2012 A WARNING Only qualified service technicians should install and service the icemaker To obtain the name and phone number of your local Hoshizaki Certified Service Representative visit www hoshizaki com No service should be undertaken until the technician has thoroughly read this Service Manual Failure to service and maintain the icemaker in accordance with this manual will adversely affect safety performance component life and warranty coverage and may result in costly water damage Proper installation is the responsibility of the installer Product failure or property damage due to improper installation is not covered under warranty Hoshizaki provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should the reader have any questions or concerns which have not been satisfactorily addressed please call send an e mail message or write to the Hoshizaki Technical Support Department for assistance Phone 1 800 233 1940 770 487 2331 Fax 1 800 843 1056 770 487 3360 E mail techsupport hoshizaki com HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn Hoshizaki Technical Support Department Web Site www hoshizaki com
26. LBU wire 12 hr DCT to CB K4 connector pin 2 LBU wire If 24VAC is not present confirm 24VAC at CB K2 connector pin 7 R wire to CB K4 connector pin 2 LBU wire If 24VAC is present on CB K4 connector pin 7 R wire and not on pin 8 LBU wire replace CB If 24VAC is present DV energizes and allows water from the evaporator and reservoir to drain for 20 minutes Opti Serve Model FLUSH drain LED is on Confirm 24VAC at CB K2 connector pin 10 LBU wire 12 hr DCT to CB K4 connector pin 2 LBU wire If 24VAC is not present and FLUSH LED is on CS in the ICE position replace CB If 24VAC is present DV energizes and allows water from the evaporator and reservoir to drain for 20 minutes Manual Drain Move CS to the DRAIN position Confirm 24VAC at CB K3 connector pin 3 DBU wire to CB K4 connector pin 2 LBU wire If 24VAC is not present replace CB If 24VAC is present check CS LBU wire to CB K4 connector pin 2 LBU wire If 24VAC is not present replace CS If 24VAC is present DV energizes and allows water from the evaporator and reservoir to drain 9 Shutdown When BC actuator paddle is activated BC proximity switch opens 5VDC is interrupted at CB K4 connector pin 3 GY wire and 4 V wire 150 sec shutdown sequence starts 90 seconds after BC opens Comp de energizes 60 seconds later GM de energizes If 5VDC is present from CB K4 connector pin 3 GY wire to CB connector pin 4 V wire and C
27. after the icemaker is serviced For cleaning procedures see VI Cleaning and Maintenance e When replacing evaporator assembly and water circuit components make sure there are no water leaks after the repair is complete A Service for Refrigerant Lines A WARNING e Repairs requiring the refrigeration circuit to be opened must be performed by properly trained and EPA certified service personnel e Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere e Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing NOTICE Do not leave the system open for longer than 15 minutes when replacing or servicing parts 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 e 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 Install the new drier with the arrow on the drier in the direction of the refrigerant flow e When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do
28. alve After 12 hr COM Power Supply Input lights when 10 5VAC is 1 2 Control Transformer timer terminates 24VAC 115VAC supplied to K4 connector 10 5VAC NO GM LED Gear Motor pins 1 amp 2 3 4 Bin Control and Gear Motor Control Switch ICE Protect Relay and Water Control Relay Circuit 5VDC 5 6 High Pressure Switch 5VDC Control Board Part Number 2A2649 01 14 2 LED Lights and Components The POWER LED indicates control voltage and will remain on unless a control voltage problem occurs For further details see II B Sequence of Operation Energized Time LEDs are Frequency LEDs are Cyce Relay Fil NANA Ice Purge X1 Freeze X1 X2 GM COMP GM Comp FM DV Drain X5 push button FLUSH drain 20 min Every 12 hr X6 OS Ice Water Dispense Energized Time LEDs are Frequency LEDs are DM i DM D 1 N A ce Dispense X4 Opti Serve DS 60 sec max ICE Every 12 sec of Agitating Motor X3 AM AM 0 6 sec accumulative dispense time VVater Dispense X5 Opti Serve Only VVTR DispVVV N A N A Legend AM agitating motor Comp compressor DispWV dispense water valve WTR LED on DCM 300BAH OS DM dispense motor DS dispense solenoid DV drain valve FM fan motor GM gear motor WV inlet water valve D Power Switch Control Switch and Dispense Mode Switch The power switch control switch and dispense mode switch are used to control the operation of
29. an to catch the ice and a set of scales to weigh the ice After the icemaker has operated for 10 to 20 minutes catch the ice production for 10 minutes Weigh the ice to establish the batch weight Multiply the batch weight by 144 for the total production in 24 hr B Diagnostic Procedure This diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components Before proceeding check for correct installation adequate water pressure 10 to 113 PSIG and proper voltage per unit nameplate Check that the 24VAC 1A fuse and the 10 5VAC 0 5A fuse are good When checking high voltage 115VAC always choose a neutral W wire to establish a good neutral connection When checking low voltage 24VAC and 10 5VAC always choose a neutral LBU wire from CT to establish a good neutral connection WARNING LBU wires are used in both high voltage and low voltage applications When checking low voltage 24VAC and 10 5VAC confirm that the neutral LBU wire being used is the LBU wire from CT not the 115VAC power LBU wire used for Comp FM operation or the 24VAC LBU wire on the control switch to GMPR DV operation When checking DC voltage 5VDC use CB K3 connector pin 1 for DC ground GND CB POWER LED remains on unless power supply is interrupted IMPORTANT icemaker will not start unless the front panel safety switch is engaged 1 Turn on the power supply Remove the front panel Move the power switch to the ON p
30. and terminal 5 DBU wire Comp and FM energize Ice production begins 4 to 6 min after Comp and FM energize depending on ambient and water temperature conditions Diagnosis 60 sec after GM energizes confirm Comp LED turns on and Comp and FM energize f not check that GMPR is energized 115VAC Next check continuity between GMPR terminal 3 BR wire and terminal 5 DBU wire If open GMPR is de energized or contacts are stuck open If closed and COMP LED Comp and FM do not energize replace CB If COMP LED turns on and Comp and FM do not energize confirm 115VAC at CB X2 relay BR wire to a neutral W wire If 115VAC is not present check connections If 115VAC is present confirm 115VAC at CB X2 relay light blue LBU wire to a neutral W wire If 115VAC is not present and COMP LED is on replace CB If 115VAC is present check Comp external protector overload allow to cool and reset If reset does not occur replace as needed Check Comp motor windings continuity and Comp capacitor Check FM for binding and FM winding continuity 11 Refill Low Water Safety As ice is produced the water level in the reservoir drops UF S opens Nothing happens at this time LF S opens FT starts WCR de energizes energizing WV Comp FM and GM continue As water fills the reservoir LF S closes Nothing happens at this time UF S closes FT terminates WCR energizes closing low water safety circuit and de energizing WV This continues un
31. anda 33 F Diagnostic Car m aaa dE e 34 V Removal and Replacement of 45 38 A Service for Refrigerant Lines eee 38 1 Refrigerant Recovery eeeeeeee AAA AAA AAA rama RR RR RR RR RR RR RR RR aran 39 E z Rhcce O OCE 39 3 Evacuation and Recharge 404 39 B Important Notes for Component Replacement 40 1 Upper Bearing Wear Check see eee 42 2 Removal and Replacement of Extruding Head eee 42 3 Removal and Replacement of Auger 43 4 Removal and Replacement of Evaporator see eee 43 5 Removal and Replacement of Mechanical Seal and Lower Housing 45 6 Removal and Replacement of Gear Motor eee 46 7 Dispense Auger and Agitator YR R YY YY ii ii iii ii rr nns nr rr rna 47 8 Dispense OF Agitating MOIOF as 47 VI Cleaning and Maintenance sese eee eee eee 48 A Cleaning and Sanitizing 6 22 r rr rr nn ner rr r nn nn 49 1 Water SY SUC IN at sk Ra b a Ba ab la KAKA 49 a Cleaning olu ARA B b cases Sete 49 b Cleaning Procedure NE eee 49 c Sanitizing Solution sss Bada a 50 d Sanitizing Procedure Following Cleaning Procedure 50 2 Dispense Components AAA A AGE Aa AKA 51 a Cleaning SOMO m adada aaa ax RKS RK
32. anical seal consists of two parts One moves along with the auger and the other is fixed on the lower housing NOTICE If the contact surfaces of these two parts are worn cracked or scratched the mechanical seal may cause water leaks and should be replaced Instructions for removing the mechanical seal and lower housing are located later in this procedure Lift off the evaporator 12 Make sure the lower mechanical seal is in place then place the new evaporator in position Secure the evaporator to the lower housing using the allen head cap screws 13 Remove the drier then place the new drier in position 14 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 15 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 16 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 17 Install the auger assembly with the upper part of the mechanical seal attached and tighten down the allen head cap screws 18 Replace the evaporator bracket and reconnect the water hoses 19 Replace spout A spout B and the front cover of the storage bin in their correct positions 20 Move the power switch to the ON position then replace the
33. ates CB energizes Comp If this circuit is open Comp cannot energize Diagnosis Check for 5VDC at CB K2 connector pin 1 DBU wire and CB K2 connector pin 2 BR wire to CB K3 connector pin 1 open If 5VDC is not present on either pin replace CB If 5VDC is present on one and not the other confirm GMPR is energized and terminals 3 and 5 contacts are closed If 5VDC is present on both once 60 sec ice purge timer terminates Comp and FM start If not replace CB e Ice Dispense Controls a Push Button Model DM and AM LEDs are on Ice Dispense Switch Dispense Mode Switch CONTINUOUS or PORTION When the ice dispense mode switch is pressed DM LED is on Circuit is closed between CB K4 connector pin 6 BK wire and 8 BK wire to 7 GY wire or 5 P wire depending on dispense mode switch CONTINUOUS or PORTION Diagnosis Check for 5VDC from CB K4 connector pin 6 BK wire or pin 8 BK wire to CB K3 connector pin 1 open If 5VDC is not present replace CB If 5VDC is present press and hold the ice dispense button DS and DM should energize If not check for 115VAC at CB K2 connector pin 6 LBU wire to a neutral W wire If 115VAC is not present check as outlined below If 115VAC is present check DS DM winding and DM auger for binding 1 CONTINUOUS Mode Engage the ice dispense button then check for 5VDC from CB K4 connector to pin 5 P wire to CB K3 connector pin 1 open If 5VDC is not pr
34. ce CB If 5VDC is present check for 5VDC from CB K4 connector pin 5 V wire to CB K3 connector pin 1 open If 5VDC is not present replace HPS or HPS wiring If 5VDC is present HPS circuit is good and WV should energize and start filling the reservoir If not see IV C 5 Fill Cycle 26 e Icemaking Control Circuit The icemaking control circuit consists of WCR CS and BC The icemaking control circuit activates once UF S closes Once CB reads a closed circuit through WCR CS and BC CB then starts the 60 sec ice purge cycle GM operation Once UF S closes WCR energizes closing contacts between WCR terminals 4 GY wire and 6 O wire CS must be in the ICE position O wires BC proximity switch must be closed O and V wires to complete the icemaking circuit between CB K4 connector pin 3 GY wire and 4 V wire Diagnosis Confirm UF S has closed and WCR energizes Next check for 5VDC from CB K4 connector pin 3 GY wire and CB K4 connector pin 4 V wire to CB K3 connector pin 1 open If 5VDC is not present on CB K4 connector pin 3 GY wire or pin 4 V wire replace CB If 5VDC is present on one and not the other check continuity on WCR terminals 4 and 6 CS and BC Freeze Protect Circuit GMPR Once 60 sec ice purge cycle starts GM and GMPR energize closing GMPR pins 3 BR wire and 5 DBU wire CB circuit K2 connector pin 1 DBU wire and 2 BR wire is now closed Once 60 sec ice purge timer termin
35. cessary U 8 9 10 11 12 Reconnect F S connector Move the power switch to the ON position Turn on the power supply Move the control switch to the ICE position Engage the safety switch Me Once the reservoir is full and GM starts disengage the safety switch then move the power switch to the OFF position and the control switch to the OFF position 13 Turn off the power supply 14 Remove F S connector and check F S continuity Both UF S and LF S should be closed Check continuity between F S common BK wire and UF S R wire Next check continuity between F S common BK wire and LF S DBU wire If either are open follow the steps in IV E 2 Float Switch Cleaning After cleaning F S check UF S and LF S again Replace if necessary 15 Reconnect F S connector 16 17 18 Move the power switch to the ON position and the control switch to the ICE position Replace the front panel in its correct position Ne NN o Turn on the power supply to start the automatic icemaking process 32 2 Float Svvitch Cleaning Depending on local vvater conditions scale may build up on F S Scale on F S can cause inconsistent operation of UF S and LF S In this case both UF S and LF S should be cleaned and checked 1 Move the control switch to the OFF position 2 Remove the front panel then move the power switch to the OFF position 3 Turn off the power su
36. ctionation Place the service cylinder on the scales if the service cylinder is not equipped with a dip tube invert the service cylinder then place it on the scales Open the high side valve on the gauge manifold 7 Allow the system to charge with liquid until the proper charge weight is met 8 If necessary add any remaining charge to the system through the low side NOTICE To prevent compressor damage use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low side access valve with the icemaker running 9 Close the high and low side gauge manifold valves then disconnect the gauge manifold hoses 10 Cap the access valves to prevent a possible leak B Important Notes for Component Replacement NOTICE When replacing a component listed below see the notes to help ensure proper operation Component Nts Install a new drier start capacitor and start relay Expansion Valve e Install a new drier e Attach the expansion valve bulb to the suction line in the same location as the previous bulb e The bulb should be between the 10 and 2 o clock positions on the tube e Secure the bulb with the clamp and holder then insulate it Upper and Inspect the upper bearing for wear See V B 1 Upper Bearing Wear Check Replace if Lower Bearings necessary When replacing the upper bearing it is advised to also change the lower bearing at the same time Evaporator e Instal
37. ctor Manual Reset Circuit Breaker Auto Reset High Pressure Switch Float Switch and Timer Spare Fuse Legs VOLTAGE RANGE 104 127VAC 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 7 II General information A Construction 1 lcemaker G o c o 6 20 5 P O o o o Q 2 o lt L G o o G Qe o o o N Q lt G O o 2 QD D Og Q 00 V LA k PL NAN Proximity Switch gt BT a p Safety Switch g 8 5 5 O Y PUI A f m fee beh FR o p 5 2 4 i N ER ST GA oz l a s R M N ARES A JM N x LC VILA BEN LLI N a 10 6 o T aj o 1 nw Va E dz vam e D Z ANECN J1 WEAK z l sin HER 10 a 74 o lt GZ W sd AS 5 2 lt wA Z ayi 3 a 42 W 5 G By O a G 2 g o o m 5 o gt ea lt Myo o c 2 5 Z i sg AE 8 3 x 8 5 2 lt 8 5 co D 5 2 Le 8 o k 2 9 S J gt W lt 8 5 5 04 o pi Dispense Water Valve Spout Cover Shutter Assembly 2 Icemaking Unit Extruding Head and Upper Bearing Auger Mechanical Seal O Ring Spline Coupling A Cutt
38. d the storage bin cover in their correct positions 6 Allow the icemaker to sit for 10 minutes before operation 7 Move the power switch to the ON position and replace the panels in their correct positions Turn on the power supply then move the control switch to the ICE position Make ice using the solution until the icemaker stops making ice 8 Move the control switch to the DRAIN position Allow the water system to drain for 5 minutes 50 9 Move the control switch to the ICE position Open the icemaker water supply line shut off valve to supply water to the reservoir 10 After the gear motor starts move the control switch to the DRAIN position Allow the water system to drain for 5 minutes 11 Move the control switch to the ICE position Allow the icemaker to run for 30 minutes then clean and sanitize the dispense components as outlined below 2 Dispense Components Perform after cleaning and sanitizing the water system as outlined above a Cleaning Solution Dilute 9 6 fl oz 0 29 1 of Hoshizaki Scale Away with 1 6 gal 6 0 1 of warm water b Sanitizing Solution Dilute 0 82 fl oz 25 ml of a 5 25 sodium hypochlorite solution chlorine bleach with 1 6 gal 6 0 1 of warm water c Cleaning and Sanitizing Procedure 1 Move the control switch to the OFF position then turn off the power supply 2 Remove the front and top panels then move the power switch to the OFF position 3 Remove the stora
39. e Solenoid and Motor 115VAC 7 Control Transformer 24VAC 8 FLUSH drain LED Drain Valve After 12 hr timer terminates 24VAC K1 Connector COM Power Supply Input 115VAC NO and Gear Motor Protect Relay e Ice Dispense Time Control Counter Reset Button not used in this application 031 1X O EM L mz LL AWIL 450 H 6 N N Z 2 1 Pag 2 EL u 6 25 Say 5 43 LAS I a 5 L HSTi 1 i B 9 Z 8 d E gt 2 ooocoooo ZE 7 2 E m is dwpJ WOJ ON HZMOd gt H S oojo aag Ja CS ON LHM O O O 3715B000 GM LED Gear Motor POWER LED green lights when 10 5VAC is supplied to K4 connector pins 1 amp 2 Control Board Part Number 2A1592 01 13 e Relay LEDs red indicate which relays and connector pins are energized e FLUSH drain LED X5 Relay K2 Connector Pin 8 12 hr Drain Timer K3 Connector Pin 3 Control Switch DRAIN Position s DM LED X4 Relay K2 Connector Pin 6 s AM LED X3 Relay K2 Connector Pin 4 s COMP LED X2 Relay X2 Relay Terminals 115VAC s GM LED X1 Relay K1 Connector Pin NO K4 Connector 1 2 Control Transformer 10 5VAC 3 4 Bin Control Control Switch ICE and Water Control Relay Circuit 5VDC 5 Ice Dispense Continuous Operation 5VDC 6 8 Ice Dispense Switch and Dispense Mode Switch 5VDC 7 Ic
40. e Dispense Portion Operation 5VDC 9 10 High Pressure Switch 5VDC b DCM 300BAH OS DCM OS Opti Serve Model Control Board Relay LEDs red indicate which relays and connector pins are e Ice Dispense Time Control energized FLUSH drain LED X6 Relay K2 Connector Pin 10 12 hr Drain Timer K3 Connector Pin 3 Control Switch DRAIN Position WTR LED X5 Relay K2 Connector Pin 8 ICE LED X4 Relay K2 Connector Pin 6 K3 Connector 3 24VAC Output to Control Switch Inlet Water Valve Water Control Relay and Drain Valve du dSid 031 LX3 e COUNTER RESET Button not used in this application e FLUSH drain Switch Do not adjust AM LED X3 Relay K2 Connector K2 Connector Pin 4 1 2 Gear Motor Protect Relay Circuit 3 o O un gt w N COMP LED X2 Relay X2 Relay Terminals 115VAC 5VDC G 3 Power Supply Input e GM LED X1 Relay 115VAC K1 Connector Pin NO 4 AM LED Agitating Motor 115VAC 5 Power Supply Input K5 Connector 115VAC 1 2 3 Ice Dispense 6 ICE LED Ice Dispense Solenoid and Motor Mode Switch Portion Operation 5VDC 115VAC 4 5 6 Ice Dispense 7 9 Control Transformer Mode Switch Continuous 24VAC Operation 5VDC 8 WTR LED 7 8 9 Water Dispense Water Dispense Valve Sensor 5VDC 24VAC 10 FLUSH drain LED e K1 Connector e POWER LED green K4 Connector Drain V
41. e table below when the Opti Serve sensor is engaged and ice is not dispensed check CB K2 connector pin 6 LBU wire for 115VAC If 115VAC is not present replace CB If 115VAC is present check DS and DM continuity Replace as needed Control Board Connector Control Board DC Ground Disengaged Engaged K5 Pin 1 W R wire OVDC OVDC K5 Pin 2 VV BU wire To K3 Pin 1 open 5VDC OVDC K5 Pin 3 W BK wire 5VDC 5VDC 28 e Water Dispense Switch Water Dispense Sensor a Push Button Model The water dispense button and DispWV are not associated with CB Engage the water dispense button then check for 24VAC at DispVVV If 24VAC is present and no water is dispensed check for water supply line shut off valve closed clogged water filters clogged WV screen If the water supply is good replace DispVVV If 24VAC is not present check water dispense switch continuity and CT 24VAC fuse 125VAC power supply and continuity b Opti Serve Model Before engaging the water dispense Opti Serve sensor check for 5VDC from the locations given in the table below If VDC is different than in the table replace CB If 5VDC is present engage the Opti Serve sensor and confirm that VDC matches the table below If not see IV F 3c Water Dispense to rule out a faulty Opti Serve sensor If the Opti Serve sensor checks out replace CB If VDC matches the table below when the Opti Serve sensor is engaged check for 24VAC between CB K2 connector pin 8 D
42. ead and the lower bearing in the housing should be replaced Instructions for removing the extruding head and housing Fig 3 are located later in this procedure Note Replacing the bearing requires a bearing press adaptor If one is not available replace the whole extruding head and housing 4 Replace the cutter spout A spout B and the front cover of the storage bin in their correct positions 5 Move the power switch to the ON position then replace the panels in their correct positions 6 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 2 Removal and Replacement of Extruding Head 1 Move the control switch to the DRAIN position and drain all of the water from the evaporator 2 After the water has stopped draining move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 3 Remove the front cover of the storage bin Remove spout B then remove spout A and the cutter See Fig 2 4 Remove the apron panel then remove the left side panel 5 Remove the allen head cap screws and lift off the extruding head 6 Place the new extruding head in place and tighten down the allen head cap screws 7 Replace the cutter in its correct position 8 Replace spout A spout B and the front cover of the storage bin in their correct positions
43. ensor signal 3a Ice Dispense Continuous Control Board Sensor To Control Board Other Sensor Engaged Disengaged K2 Pin 6 LBU wire Tol Neutral GND 120VAC OVAC W wi VD Sensor KB Pin 4 W 0 wire R wire To a Net wre 7 K5 Pin 6 W BR wire BK wire 5VDC 5VDC 3b Ice Dispense Portion Control Board Sensor To Control Board Other Sensor Engaged Disengaged K2 Pin 6 LBU wire To Neutral GND 120VAC OVAC K5 Pin 2 W BU wire 5VDC OVDC u K5 Pin 3 W BK wire BK wire 5VDC 5VDC 3c VVater Dispense Componentl Control Board To Control Board Other Engaged Disengaged Solenoid K2 Pin 8 DBU wire K4 Pin 2 LBU wire 24VAC OVAC K5 Pin 8 VV vvire 5VDC OVDC lta wai K5 Pin 9 BK wire 5VDC 5VDC 37 V Removal and Replacement of Components A WARNING e This icemaker should be diagnosed and repaired only by qualified service personnel to reduce the risk of death electric shock serious injury or fire e Move the power switch to the OFF position and turn off the power supply to the icemaker before servicing Lockout Tagout to prevent the power from being turned back on inadvertently e CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after the equipment is serviced Make sure that none have fallen into the storage bin e Make sure all food zones in the icemaker and storage bin are clean
44. ent and the POWER LED is off replace CB If 10 5VAC is not present see IV B 7 Startup 4 5VDC Output Checks There are 6 CB circuits utilizing 5VDC high pressure switch icemaking control circuit freeze protect circuit ice dispense switch dispense mode switch CONTINUOUS or PORTION and the water dispense switch water dispense sensor Opti Serve model only The high pressure switch and the icemaking control circuit can prevent CB from starting the icemaking process e High Pressure Switch CB must have continuity through HPS to start the icemaking process HPS is a normally closed switch Before proceeding to CB check confirm HPS condition Turn off the power supply then remove HPS wires and check continuity across HPS If open allow to reset If HPS does not reset see IV B 10 Freeze Cycle a Push Button Model If HPS closed check for 5VDC from CB K4 connector pin 10 V wire to CB K3 connector pin 1 open If 5VDC is not present and POWER LED is on replace CB If 5VDC is present check for 5VDC from CB K4 connector pin 9 BR wire to CB K3 connector pin 1 open If 5VDC is not present replace HPS or HPS wiring If 5VDC is present HPS circuit is good and WV should energize and start filling the reservoir If not see IV C 5 Fill Cycle b Opti Serve Model If HPS closed check for 5VDC from CB K4 connector pin 6 BR wire to CB K3 connector pin 1 open If 5VDC is not present and POWER LED is on repla
45. er il 1 5 m RR bb Seal Bolts and Washers Evaporator 12 Pa pms C ff _ 9 Socket Head Screvv and Split Lock Washer Housing and Lower Bearing Hex Bolt and Washer Gear Motor Socket Head Cap Screw and Split Lock Washer B Sequence of Operation oh Sequence Cycles and Shutdown The steps in the sequence are as outlined below When power is supplied power switch is in the ON position safety switch is engaged and the control switch is in the ICE position CB POWER LED turns on The POWER LED indicates control voltage and will remain on unless a control voltage problem occurs If icemaker does not start BC actuator and proximity switch may be engaged Move the dispense mode switch to the CONTINUOUS position then dispense ice to lower the level of ice in the storage bin a Fill Cycle Reservoir is empty LF S and UF S are open WV energizes and fill cycle starts LF S closes Nothing happens at this time Reservoir continues to fill until UF S closes When UF S closes WCR energizes closing low water safety circuit and de energizing WV GM energizes once UF S closes b Ice Purge Cycle GM LED is on GM energizes 60 sec ice purge timer starts Note GM cannot energize unless UF S is closed c Freeze Cycle COMP and GM LEDs are on 60 sec ice purge timer terminates GM continues CB confi
46. esent check ice dispense switch and DMS continuity 2 PORTION Mode Engage the ice dispense button then check for 5VDC from CB K4 connector pin 7 GY wire to CB K3 connector pin 1 open If 5VDC is not present check the ice dispense switch and DMS continuity 27 b Opti Serve Model ICE and AM LEDs are on 1 CONTINUOUS Mode Before engaging the ice dispense Opti Serve sensor check for 5VDC from the locations given in the table belovv f VDC is different than in the table replace CB If VDC is correct engage the Opti Serve sensor and confirm that VDC matches the table below If not see IV F 3a Ice Dispense CONTINUOUS Mode to rule out a faulty Opti Serve sensor If the Opti Serve sensor checks out replace CB If VDC matches the table below when the Opti Serve sensor is engaged and ice is not dispensed check CB K2 connector pin 6 LBU wire for 115VAC If 115VAC is not present replace CB If 115VAC is present check DS and DM continuity Replace as needed OVDC K5 Pin 6 W BR wire 2 PORTION Mode Before engaging the ice dispense Opti Serve sensor check for 5VDC from the locations given in the table below If VDC is different than in the table replace CB If VDC is correct engage the Opti Serve sensor and confirm that VDC matches the table below If not see IV F 3b Ice Dispense PORTION Mode to rule out a faulty Opti Serve sensor If Opti Serve sensor checks out replace CB If the VDC matches th
47. ge bin cover 4 Remove the motor bracket thumbscrews first from the vertical plane and then from the horizontal plane While holding on to the corresponding agitator or auger move the agitating motor or the dispense motor towards you Remove the agitator and the dispense auger from the storage bin See Fig 5 5 Remove the bin control assembly See Fig 6 6 Remove the snap pin shaft and actuator 7 Remove spout B spout A and their gaskets Spout B Spout A Bin Control Assembly Bin Control Bracket Snap Pin Actuator 8 Remove the spout cover ice dispense spout and vvater dispense nozzle See Fig 7 9 Immerse the agitator dispense auger and parts removed in steps 5 through 8 in the cleaning solution and then in the sanitizing solution for 15 minutes each Rinse the parts thoroughly with clean water On Opti Serve models OS wipe the optical sensors with cleaning solution and then with a clean damp cloth 10 Wipe the shutter located above the ice dispense spout thoroughly with a clean cloth 11 Reassemble the bin control assembly and replace all parts in the reverse order of which they were removed 12 Pour warm water into the storage bin and melt any remaining ice Clean the storage bin liner and the storage bin cover using a neutral cleaner Rinse thoroughly after cleaning Replace the storage bin cover in its correct position 13 Move the power switch to the ON position the
48. instruction concerning use of the appliance by a person responsible for their safety e Children should be properly supervised around this appliance NOTICE Follow the instructions in this manual carefully to reduce the risk of costly water damage e n areas where water damage is a concern install in a contained area with a floor drain e Install the icemaker in a location that stays above freezing Normal operating ambient temperature must be within 45 F to 100 F 7 C to 38 C e Do not leave the icemaker on during extended periods of non use extended absences or in sub freezing temperatures To properly prepare the icemaker for these occasions follow the instructions in VI C Preparing the Icemaker for Periods of Non Use e Keep ventilation openings in the appliance enclosure or in the built in structure clear of obstruction Do not place objects on top of the icemaker e The storage bin is for ice use only Do not store anything else in the storage bin I Specifications A lcemaker 1 DCM 300BAH OS AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR AGITATING MOTOR DISPENSING MOTOR OTHER MAXIMUM FUSE SIZE MAX HACR BREAKER USA ONLY MAX CIRC BREAKER CANADA ONLY MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE HARDNESS FACTOR APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 10
49. ion starts to overflow into the drain pan Note If there is excess scale on the extruding head fill the evaporator assembly and reservoir as described above then use a clamp on the reservoir hose between the reservoir and evaporator assembly to block flow Pour additional cleaning solution over the extruding head until the evaporator assembly is completely full 7 Replace spout A spout B and the storage bin cover in their correct positions 8 Allow the icemaker to sit for 10 minutes before operation If you placed a clamp on the reservoir hose in step 6 remove it before operation 49 9 In bad or severe water conditions clean the float switch assembly as described below Otherwise continue to step 10 a Remove the float switch assembly from the reservoir cover b Wipe down the float switch assembly with the cleaning solution c Rinse the float switch assembly thoroughly with clean water d Replace the float switch assembly in its correct position 10 Move the power switch to the ON position and replace the panels in their correct positions Turn on the power supply then move the control switch to the ICE position Make ice using the solution until the icemaker stops making ice Note This icemaker will not run if the safety switch is not engaged 11 Move the control switch to the DRAIN position Allow the water system to drain for 5 minutes 12 Move the control switch to the ICE position Open the icemaker water s
50. ions in Pan and Gear this manual into the evaporator condensate drain pan Be careful not to Motor Drain Pan overflow the pan This solution will flow down to the gear motor drain pan and out the drain line to sanitize these areas Repeat with a cup of clean water to rinse Icemaker Storage Check to make sure they are clear Bin and Drip Tray Drains Yearly Inlet Water Valve Close the water supply line shut off valve and drain the water system Clean and Drain Valve the inlet water valve screen and clean and inspect the drain valve Inspect the water hoses and clean replace if necessary Condenser Inspect Clean if necessary by using a brush or vacuum cleaner cemaker nspect for oil spots loose componenis fasteners and vvires Upper Bearing Check for vvear using 02 round stock or pin gauge Replace both upper extruding head bearing and lovver bearing if vvear exceeds factory recommendations See V B 1 Upper Bearing VVear Check After Upper Bearing Inspect Replace both upper bearing and lower bearing if wear exceeds 3 Years extruding head factory recommendations Replace the mechanical seal if the seal s contact then Yearly Lower Bearing surfaces are worn cracked or scratched and O Ring lower housing Mechanical Seal Evaporator Cylinder Auger 53 C Preparing the Icemaker for Periods of Non Use NOTICE When storing the icemaker for an extended time or in sub freezing temperatures follow the inst
51. ive If 24VAC is present check for 24VAC at GMPR terminal 2 P wire to a neutral LBU wire If 24VAC is not present check GMPR continuity between terminals 2 P wire and 6 LBU wire If open replace GMPR Next check for 24VAC at DV If 24VAC is present and DV does not energize check DV solenoid continuity 13 Shutdown Bin fills with ice and activates BC actuator paddle 150 sec shutdown sequence begins 90 sec after BC opens Comp and FM de energize AM energizes for 0 6 sec 60 sec later GM de energizes Diagnosis Check that BC actuator paddle is activated and not sticking Check BC proximity switch continuity to confirm BC proximity switch is open If BC actuator is engaged and BC proximity switch is closed replace BC proximity switch If BC proximity switch is open and Comp FM and GM do not de energize replace CB See IV C Control Board Check Procedure Legend AM agitating motor BC bin control CB control board Comp compressor CT control transformer DCT drain cycle timer 12 hr timer DV drain valve DVT drain valve timer 20 min timer FM fan motor FT fill timer 90 sec low water safety GM gear motor GMPR gear motor protect relay LF S lower float switch UF S upper float switch VVCR vvater control relay WV inlet water valve 25 C Control Board Check Before replacing CB that does not shovv a visible defect and that you suspect is bad conduct the following CB check This procedure will
52. l a new drier e Inspect the mechanical seal and O ring prior to installing the new evaporator If worn cracked or scratched the mechanical seal should also be replaced Gear Motor Install a new gear motor capacitor 40 Evaporator Assembly Cutter Extruding Head and Upper Bearing Auger gt U o o gt Evaporator Allen Head Cap Screw with Washer Mechanical Seal Ring O Ring Housing and Lower Bearing Hex Head Bolt with Washer Spline Coupling Fig 2 Gear Motor 41 1 Upper Bearing VVear Check To ensure that the bearing inside the extruding head does not exceed the vvear tolerance Of 02 follovv the instructions belovv See Fig 3 1 Move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the povver svvitch to the OFF position 2 Remove the front cover of the storage bin Remove spout B then remove spout A and the cutter See Fig 2 02 Round Stock or Pin Gauge 3 Grasp the top of the auger and move the auger towards you then try to insert a 02 round stock or pin gauge in between the back side of the auger shaft and the bearing surface Check several locations around the auger shaft If the gauge goes between the shaft and the bearing at any point or if the bearing is scratched or cracked both the top bearing in the extruding h
53. l not to damage the surfaces of the O ring or mechanical seal 5b Lower Housing 11 Remove the O ring and the bolts securing the housing to the gear motor and remove the housing from the gear motor If inspection of the upper bearing inside the extruding head see V D 1 Upper Bearing Wear Check indicates that it is out of tolerance replace both it and the bearing inside the lower housing Note Replacing the bearing requires a bearing press adaptor If one is not available replace the whole extruding head and housing 12 13 14 15 16 17 Install the O ring and mount the lower housing on the gear motor Install the lower part of the mechanical seal on the lower housing Lower the evaporator down and secure it to the lower housing Install the auger assembly with the upper part of the mechanical seal attached Replace the evaporator bracket in its correct position 6 5 Replace spout A spout B and the front cover of the storage bin in their correct positions 18 Move the power switch to the ON position then replace the panels in their correct positions 19 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 45 6 Removal and Replacement of Gear Motor 1 Move the control svvitch to the DRAIN position and drain all of the vvater from the evaporator 2 After the water has stopped draining move the control switch to the OFF
54. mbscrews from the vertical plane then loosen the thumbscrews from the horizontal plane of the motor bracket Slide the motor back Note Hold the dispense auger agitator to prevent it from dropping when sliding back the motor See Fig 4 4 Replace the dispense auger agitator with the new one 5 Assemble the removed parts in the reverse order of which they were removed 6 Move the power switch to the ON position then replace the panels in their correct positions 7 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 8 Dispense or Agitating Motor 1 Move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 2 Remove the storage bin front panel 3 Remove the thumbscrews from the vertical plane then loosen the thumbscrews from the horizontal plane of the motor bracket Slide the motor back Note Hold the dispense auger agitator to prevent it from dropping when sliding back the motor See Fig 4 4 Remove the thumbscrews from the horizontal plane of the motor bracket 5 Remove the motor from the bracket 6 Install the new motor 7 Assemble the removed parts in the reverse order of which they were removed Agitator Agitating Motor 8 Move the power switch to the ON position then replace the panels in their correct positions
55. mo eq l O UAA 1 21 99S JU ZL Aisne ull OZ 104 suado Ad ureuq HZ L E SO HY 00 INOG Heyo MO 4 aduenbas peog 044409 SO WIA PUL dd NOQ lt l v sulBag dnes C Control Board e A Hoshizaki exclusive control board is employed in Hoshizaki icemakers e All models are pre tested and factory adjusted e For a control board check procedure see IV C Control Board Check Procedure NOTICE e The control board is fragile handle very carefully e The control board contains integrated circuits which are susceptible to failure due to static discharge It is especially important to touch the metal part of the icemaker before handling or replacing the control board Do not touch the electronic devices on the control board or the back of the control board e Do not change wiring and connections Do not misconnect terminals e Do not short out power supply to test for voltage e Always replace the whole control board assembly if it goes bad 12 1 Control Board Layout a DCM 300BAH DCM PB Push Button Model Control Board FLUSH drain Switch Do not adjust K3 Connector 113 24VAC Output to Control Switch Inlet Water Valve Water Control Relay and Drain Valve K2 Connector 1 2 Gear Motor Protect Relay Circuit 5VDC 3 Power Supply Input 115VAC 4 AM LED Agitating Motor 115VAC 5 Power Supply Input 115VAC 6 DM LED Ice Dispens
56. n replace the panels in their correct positions Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 1 SV Ice Dispense Spout Spout Cover Fig 7 52 B Maintenance The maintenance schedule belovv is a guideline More frequent maintenance may be required depending on vvater quality the icemaker s environment and local sanitation regulations A WARNING e Only qualified service technicians should service this icemaker e Move the control switch and the power switch to the OFF position and turn off the power supply before servicing Lockout Tagout to prevent the power supply from being turned back on inadvertently Maintenance Schedule Frequeneylarsa TRS Every 2 Air Filter Inspect Wash with warm water and neutral cleaner if dirty Weeks Monthly External Water Check for proper pressure and change if necessary Filters Icemaker Exterior Wipe down with a clean soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up Clean any chlorine staining rust colored spots using a non abrasive cleaner like Zud or Bon Ami Every 6 Icemaker and Clean and sanitize per the cleaning and sanitizing instructions provided in Months Storage Bin this manual Evaporator Wipe down with a clean cloth and warm water Slowly pour one cup of Condensate Drain sanitizing solution prepare as outlined in the sanitizing instruct
57. not allow the drier to exceed 250 F 121 C 38 1 Refrigerant Recovery This icemaker is provided vvith refrigerant access valves Using proper refrigerant practices recover the refrigerant from the service valves and store it in an approved container Do not discharge the refrigerant into the atmosphere 2 Brazing A WARNING s R 404A itself is not flammable at atmospheric pressure and temperatures up to 176 F 80 C e 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 e Do not use silver alloy or copper alloy containing arsenic e Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 1 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG NOTICE e 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 Install the new drier with the arrow on the drier in the direction of the refrigerant flow e When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not all
58. nuity between CB connector K4 pin 3 GY wire and 4 V wire Next confirm 115VAC at CB K1 connector COM BR wire to a neutral W wire If 115VAC is present at CB K1 connector COM BR wire but not on NO DBU wire and CB K4 connector pin 3 GY wire and 4 V wire are closed replace CB 7 Freeze Cycle GM and COMP LEDs are on 60 sec ice purge timer terminates CB X2 relay energizes closing X2 relay contacts BR and LBU wires Confirm continuity between CB K2 connector pin 1 DBU wire and 2 BR wire After being closed for 60 seconds confirm 115VAC between X2 BR wire and a neutral W wire Next check for 115VAC between CB X2 LBU wire and a neutral W wire If 115VAC is present on CB X2 BR wire but not on CB X2 LBU wire and CB K2 connector pin 1 DBU wire and 2 BR wire are closed replace CB 29 8 Drain Cycle FLUSH drain LED is on 12 hr DCT terminates or CS is moved to DRAIN position 150 sec shutdown sequence starts 90 seconds later Comp de energizes and Comp LED turns off 60 seconds after Comp de energizes GM de energizes and GM LED turns off Drain cycle starts FLUSH LED turns on and DV energizes DV de energizes after 20 minutes when drain cycle is initiated by 12 hr DCT When the drain cycle is initiated by CS manual drain DV de energizes when CS is moved to OFF position or ICE position Push Button Model FLUSH drain LED is on Confirm 24VAC at CB K2 connector pin 8
59. omp or GM does not de energize replace CB Legend AM agitating motor BC bin control CB control board Comp compressor CS control switch CT control transformer DCT drain cycle timer 12 hr timer DispVVV dispense water valve DM dispense motor DMS dispense mode switch CONTINUOUS or PORTION DS dispense solenoid DVT drain valve timer 20 min timer FM fan motor GM gear motor GMPR gear motor protect relay LF S lovver float switch UF S upper float switch WCR water control relay WV inlet water valve 30 D Bin Control Check 1 Remove the front and top panels 2 Remove the storage bin cover f necessary dispense ice so that the BC actuator is not engaged or remove the ice manually WARNING Care should be taken to avoid the agitator during BC testing 3 Move the control svvitch to the OFF position 4 Move the power switch to the OFF position 5 Turn off the power supply 6 Disconnect red BC connector from the back of the control box 7 Check for continuity across BC proximity switch violet V wire and orange O wire If BC actuator is not engaged and BC proximity switch is open replace BC proximity switch 8 Press and hold BC actuator paddle While BC actuator is engaged check for continuity across BC proximity switch violet V wire and orange O wire If BC actuator is engaged and BC proximity switch is closed replace BC proximity switch 9 Disengage BC actuator
60. osition then move the control switch to the DRAIN position Engage the safety switch 2 Allow the water system to drain for 5 minutes If water does not drain from the icemaker see step 12 Drain Cycle below 3 Disengage the safety switch then move the control switch to the OFF position 4 5 6 Engage the safety switch Move the power switch to the OFF position Remove the control box cover 21 7 Startup Move the power switch to the ON position then move the control switch to the ICE position to start the automatic icemaking process Diagnosis Check that CB POWER LED is on If not check for proper power supply voltage 115VAC input to CT If 115VAC is not present check the breaker power switch and front panel safety switch Next check that the power protect relay is de energized and contacts between terminals 6 BR wire and 2 BK wire are closed Check for proper control voltage 10 5VAC output from CT to CB K4 connector pin 1 BR wire to CB K4 connector pin 2 LBU wire If 10 5VAC is not present and 10 5VAC 0 5A fuse is good replace CT If 10 5VAC is present and POWER LED is off replace CB 8 Fill Cycle Reservoir is empty LF S and UF S are open WV energizes and fill cycle starts LF S closes Nothing happens at this time Reservoir continues to fill UF S closes WCR energizes closing low water safety circuit WCR terminals 6 GY wire and 4 O wire and de energizing WV GM
61. ow the drier to exceed 250 F 121 C 2 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 3 Evacuation and Recharge R 404A 1 Attach 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 Open the gauge manifold valves Never allow the oil in the vacuum pump to flow backwards 3 Allow the vacuum pump to pull down to a 29 9 Hg vacuum Evacuating period depends on pump capacity 39 4 Close the lovv side valve and high side valve on the gauge manifold 5 Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder Remember to loosen the connection and purge the air from the hose See the rating label inside the icemaker for the required refrigerant charge Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 latest edition be used 6 A liquid charge is required for charging an R 404A system to prevent fra
62. paddle 10 Connect red BC connector 11 Turn on the power supply Move the power switch to the ON position 12 Move the control switch to the ICE position 13 14 15 The 150 sec shutdown sequence starts 90 seconds after BC opens Comp de energizes 60 seconds later GM de energizes If 5VDC is present at CB K4 connector pin 3 GY wire to 4 V wire and Comp or GM does not de energize replace CB Engage the safety switch to start the automatic icemaking process When Comp starts press and hold BC actuator paddle Legend BC bin control CB control board Comp compressor GM gear motor 31 E Float Switch Check and Cleaning 1 Float Switch Check 1 Remove the front panel then make sure the power switch is in the ON position 2 Move the control switch to the DRAIN position 3 Engage the safety switch and allow the evaporator and reservoir to drain 4 Disengage the safety switch then move the power switch to the OFF position and the control switch to the OFF position 5 Turn off the power supply 6 Disconnect F S connector and check F S continuity Both UF S and LF S should be open Check continuity between F S common BK wire and UF S R wire Next check continuity between F S common BK wire and LF S DBU wire If both are open continue to step 7 If either are closed follow the steps in IV E 2 Float Switch Cleaning After cleaning F S check UF S and LF S again Replace if ne
63. pply 4 Remove F S assembly from the reservoir cover See Fig 1 5 Wipe down F S assembly with a mixture of 1 part Hoshizaki Scale Away and 25 parts warm water Rinse the assembly thoroughly with clean water 6 While not necessary the floats can be removed from the shaft during cleaning If you remove them note that the blue float is on top UF S and the white float is on bottom LF S The floats must be installed with the magnets inside them towards the top of the switch See Fig 1 Installing the floats upside down will affect the timing of F S operation 7 Rinse F S assembly thoroughly with clean water and replace in its correct position 8 9 10 11 Move the control svvitch to the ICE position to start the automatic icemaking process Move the power switch to the ON position Replace the front panel in its correct position Turn on the power supply Legend F S float switch GM gear motor LF S lower float switch UF S upper float switch Float Switch Assembly Red upper Black common Dark Blue lovver I Reservoir Cover Ke Magnet towards top Upper Float blue Spring Retainer Clip Magnet towards top Lower Float white Plastic Retainer Clip Reservoir Fig 1 33 F Diagnostic Charts Before consulting the diagnostic charts check for correct installation proper voltage per unit nameplate and adequate vvater pressure 10 to 113 PSIG Check CB
64. reduce the risk of electric shock do not touch the control switch or power switch with damp hands e Before Servicing To reduce the risk of electric shock move the control switch to the OFF position then move the power switch to the OFF position Turn off the power supply Lockout Tagout to prevent the power supply from being turned back on inadvertently e This icemaker must be installed in accordance with applicable national state and local codes and regulations Failure to meet these code requirements could result in death electric shock serious injury fire or severe damage to equipment e This icemaker requires an independent power supply of proper capacity See the nameplate for electrical specifications Failure to use an independent power supply of proper capacity can result in a tripped breaker blown fuse damage to existing wiring or component failure This could lead to heat generation or fire e THIS ICEMAKER MUST BE GROUNDED Failure to properly ground the icemaker could result in death or serious injury Do not make any alterations to the icemaker Alterations could result in electric shock injury fire or damage to the icemaker e Do not place fingers or any other objects into the ice discharge opening e This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or
65. rms GM operation through GMPR terminal 3 BR wire and terminal 5 DBU wire then Comp and FM energize Ice production starts 4 to 6 min after Comp energizes depending on ambient and water temperature conditions UF S and LF S operate WV as needed to continue the icemaking process Refill As ice is produced the water level in the reservoir drops UF S opens Nothing happens at this time LF S opens FT starts WCR de energizes energizing WV As water fills the reservoir LF S closes Nothing happens at this time Water continues to fill and UF S closes FT terminates and WCR energizes closing low water safety circuit and de energizing WV If UF S remains open longer than 90 sec after LF S opens FT exceeded Comp and FM de energize GM de energizes 60 sec later WV remains energized until UF S closes The freeze cycle continues until BC shuts the icemaker down a drain cycle occurs or power is turned off to the icemaker d Drain Cycle FLUSH LED is on The drain cycle occurs once every 12 hrs for 20 min 12 hr DCT terminates DVT starts Comp and FM de energize GM de energizes 60 sec later DV energizes DV remains energized for the remainder of the drain cycle e Shutdown BC activates 150 sec shutdown sequence starts After 90 sec Comp and FM de energize AM energizes for 0 6 seconds 60 sec later GM de energizes Legend AM agitating motor BC bin control CB control board Comp compressor DCT drain cycle timer
66. ructions below to prevent damage When the icemaker is not used for two or three days under normal conditions it is sufficient to only move the control switch to the OFF position When storing the icemaker for extended time or in sub freezing temperatures follow the instructions below 1 Close the icemaker water supply line shut off valve and open the icemaker water supply line drain valve 2 Move the control switch to the DRAIN position Allow the water system to drain for 5 minutes 3 Move the dispense mode switch to the CONTINUOUS position then dispense all of the ice from the storage bin Note Ice dispenses continuously for a maximum of 60 seconds per activation 4 Attach a compressed air or carbon dioxide supply to the icemaker water supply line drain valve 5 While engaging the water dispense switch blow out the water dispense valve using the compressed air or carbon dioxide supply After blowing out the water dispense valve leave the compressed air or carbon dioxide supply flowing Move the control switch to the ICE position to open the inlet water valve and briefly blow out the inlet water valve After blowing out the inlet water valve move the control switch to the OFF position 6 Close the icemaker water supply line drain valve 7 Turn off the power supply then remove the front panel and move the power switch to the OFF position 8 Remove the storage bin cover Clean the storage bin liner and the
67. this icemaker 1 Power Switch The power switch has 2 positions OFF and ON WARNING 115VAC power supply is present on control board K1 connector pin COM and the control board X2 relay gear motor BR wire when the power switch is in the OFF position When the power switch is in the OFF position no power is 2 a supplied to the control transformer or control board K2 connector ZE pin 3 and the K2 connector pin 5 OFF When the power switch is in the ON position 115VAC power supply is directed to the control transformer and control board K2 connector pin 3 BK wire and pin 5 BK wire The control board then directs 24VAC from the K3 connector pin 3 DBU wire to one side of the double pole double throw control switch at the same time the control board directs 5VDC from the K4 connector pin 4 V wire to the other side of the control switch 15 2 Control Svvitch The control switch is a double pole double throvv switch with 3 positions ICE OFF and DRAIN a ICE VVhen the control svvitch is in the ICE position the control svvitch directs 5VDC from control board K4 connector pin 3 to control board K4 connector pin 4 When the control board receives 5VDC on K4 connector pin 4 the icemaking process starts b DRAIN When the control switch is in the DRAIN position the control switch directs 24VAC power supply to the drain valve and breaks the 5VDC to the control board K4 connector pin 4
68. til BC shuts the icemaker down a drain cycle occurs or power is turned off to the icemaker Diagnosis Confirm that the water level has dropped and UF S and LF S are open See IV E Float Switch Check and Cleaning Check that the reservoir fills If not check for water supply line shut off valve closed clogged water filters dirty or sticking F S clogged WV screen defective WCR defective WV coil and DV leaking by For further information see IV B 8 Fill Cycle If UF S remains open longer than 90 sec after LF S opens FT exceeded Comp and FM de energize GM de energizes 60 sec later WV continues until UF S closes 23 12 Drain Cycle FLUSH drain LED is on The icemaker drains the evaporator and reservoir once every 12 hr A manual drain is provided vvhen cleaning the icemaker by moving the control switch from the ICE position to the DRAIN position a Automatic Drain Cycle A drain cycle occurs once every 12 hr for 20 min DCT terminates and DVT starts If the icemaker is not running when DCT terminates DV energizes immediately If the icemaker is running when DCT terminates Comp and FM de energize GM de energizes 60 sec later then DV energizes Once DVT terminates DCT resets and DV de energizes Fill cycle starts DCT resets every time the power supply is turned off and on again Diagnosis Once GM de energizes DV energizes If not check for 24VAC at the control switch LBU wire to a neutral LBU wire If 24V
69. upply line shut off valve to supply water to the reservoir 13 After the gear motor starts move the control switch to the DRAIN position Allow the water system to drain for 5 minutes Note If you do not sanitize the icemaker move the control switch to the ICE position after the water system drains Allow the icemaker to run for 30 minutes then move the control switch to the OFF position Turn off the power supply then remove the front panel and storage bin cover Move the power switch to the OFF position Go to step 12 in VI A 2 c Cleaning and Sanitizing Procedure under 2 Dispense Components 14 Move the control switch to the OFF position then turn off the power supply 15 Close the icemaker water supply line shut off valve c Sanitizing Solution Dilute 0 82 fl oz 25 ml of a 5 25 sodium hypochlorite solution chlorine bleach with 1 6 gal 6 0 1 of warm water d Sanitizing Procedure Following Cleaning Procedure 1 Make sure the control switch is in the OFF position the power supply is off and the icemaker water supply line shut off valve is closed 2 Remove the front and top panels then move the power switch to the OFF position 3 Remove the storage bin cover Remove spout B then remove spout A 4 Pour the sanitizing solution over the extruding head until the evaporator assembly and the reservoir are full and the solution starts to overflow into the drain pan 5 Replace spout A spout B an
70. ve 4 Inlet Water Valve Screen or orifice clogged Coil winding open Shutdown 1 Bin Control Not enough ice in bin to trip actuator paddle ojo v 35 2 lce Water Dispense Ice Dispense Push Button 1 Power Supply a See Startup 2 Control Board a Ice dispense switch circuit open or no power b No power to ice dispense solenoid ice dispense motor or agitating motor 3 1ce Dispense Switch 4 Dispense Mode Switch 5 Ice Dispense Motor Dispense Solenoid 7 Shutter Assembly a Agitating Motor T Power Supply 2 Control Board No power to ice dispense solenoid ice dispense motor or agitating motor 3 Infrared Sensor 4 Dispense Mode Switch 5 ce Dispense Motor 6 los Dispense Solenoid 7 Shutter Assembly 8 Agitating Motor 1 Power Supply a See Startup 2 Infrared Sensor 3 Water Dispense Switch 4 Water Dispense Valve 1 Power Supply a See Startup 2 Infrared Sensor 3 Control Board 4 Water Dispense Valve 36 3 Opti Serve OS Sensors Be sure to check all items in section IV F 2 Ice VVater Dispense prior to using this chart Use the follovving charts along vvith the vviring diagram to troubleshoot the OS sensors 1 OS Sensor a Dirty b Defective See chart 3a and 3b 2 Control Board No power to infrared sensor b Not reading infrared sensor signal 1 OS Sensor Dirty Defective See chart 3c 2 Control Board No power to infrared sensor Not reading infrared s

Hoshizaki 300BAH(-OS) User's Manual

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