Hoshizaki DCM-270BAH-OS manual

SER VICE MANUAL ITEM #: 73110 CUBELET ICE DISPENSER R eliability is a beautiful thing TM ISSUED: F ebruary 10, 2004 REVISED: May 26, 2005 DCM-270BAH-OS[...]

2 IMPOR T ANT Only qualified service technicians should attempt to service or maintain this ice dispenser. No service or maintenance should be undertaken until the technician has thoroughly read this service manual. HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the dispenser. Shou[...]

3 Please review this manual. It should be read carefully before the ice dispenser is serviced or maintenance operations performed. Only qualified service technicians should service and maintain the dispenser. This manual should be made available to the technician prior to service or maintenance. CONTENTS I. Specifications ..........................[...]

4 I. Specifications 1. DCM-270B AH-OS (air -cooled) We reserve the right to make changes in specifications and design without prior notice. AC SU PP L Y VO L T AGE 1 1 5 /6 0 /1 A M P E RA GE 8. 5 A [ A T 10 4°F(40°C)/ W T 80°F (27°C)] MAX I MU M FU SE SI Z E N /A M IN IM UM CIRCUI T A M P A CIT Y N/ A APPR OX I MAT E I C E PR O D U C T I ON Am[...]

5 II. General Information 1. Construction The Hoshizaki Cubelet Ice Dispenser, model DCM-270BAH-OS includes water supply, freezer, condensing, storage, dispensing and control assemblies. Note: *Adjustable Legs Minimum height - 4" Maximum height - 5.3" Do not adjust exceeding the above recommendation. Fig. 1[...]

6 Fig. 2 2.Operation - How it works Water flows from the potable water source through the water supply line shut-off valve, enters at the water inlet fitting and into the water reservoir. The water reservoir functions to maintain a constant water level inside the freezer assembly. Water from the water reservoir enters at the bottom of the freezer. [...]

7 III. T echnical Information 1. W ater Cir cuit and Refrig erant Cir cuit[...]

8 2. P erf ormance Data [a] DCM-270BAH-OS (air-cooled) Note: Pressure data is recorded first 5 minutes in freezing cycle. The data without *marks should be used for reference. We reserve the right to make changes in specifications and design without prior notice.[...]

9 3. Wiring Diagram[...]

10 4. Sequence of Electrical Circuit POWER ON WATER STARTS TO BE SUPPLIED TO RESERVOIR AGITATION TIMER ON - (2 SEC.)[...]

11 RESERVOIR FILLS UP GEAR MOTOR TURNS ON[...]

12 COMPRESSOR STARTS 60 SEC. AFTER GEAR MOTOR.[...]

13 ICE MAKING CONTINUES. START CAPACITOR TAKEN OUT OF CIRCUIT[...]

14 BIN CONTROL TRIPS. COMPRESSOR STOPS 90 SECONDS LATER.[...]

15 GEAR MOTOR STOPS 60 SECONDS AFTER COMPRESSOR.[...]

16 DISPENSE ICE (BIN CONTROL STILL TRIPPED)[...]

17 FLUSH SWITCH ACTIVATED.[...]

18 FLUSH TIMER ACTIVATED.[...]

19 AGITATION TIMER ACTIVATES GEAR MOTOR.[...]

20 IV . Service Diagnosis 1. No Ice Production PR O BLEM PO SSIBLE CA USE R EMEDY [ 1] The ic e dispens er will not st art . a) Power S upply Cor d 1. Br ok en or loos e connec t ion. 1 . Ch e ck f or co n t in tin ui t y a nd r eplac e. 2. Lo ose c onnec t ion. 2. T ight en. 3. B ad cont ac t s. 3. Check f or cont int in uit y and r eplac e. 4. B [...]

21 PR O BLEM PO SSIBLE CA USE REMED Y [ 5] a) F an M ot or 1. Mot or winding open ed. 1. R eplac e. 2. Bearing wor n out . 2. Repl ac e. 3. Wir ing t o f an mot or. 3. C hec k f or loose c onnect io n or open, and replace. 4. F an bla de bound. 4. C hec k and r eplace. b) T im er 1. Bad c ont act s ( X2 relay) . 1. Check f or cont inu it y and r ep[...]

22 2. Low Ice Production PR O BLEM PO SSIBLE CA USE R EMEDY [ 1] Abnorm al ref rigerat ion circu i t . a) Condenser 1. Di r t y air f ilt er or condens er. 1. Clean. 2. Bad v ent ilat ion. 2. Re m ove any t hing block ing ven ts. b) T herm os t at ic Ex pans ion Val ve 1. Low-side pr ess ure or t em perat u r e exc eeding th e l i m i t. 1. Sec ur [...]

23 3. Faulty Dispenser PR O BLEM PO SSIBLE CA USE REMED Y [ 1] a) 1. I ce block or br idge. 1. Remove all ice f rom st orage bin when not us ing ice dis pens er f or a lo ng t im e. 2 . Inco rrect wi rin g . 2. C orre ct w iri ng . b) A git at or 1. Def orm ed due t o ic e block or br idge. 1. Replace. c) Solenoid 1 . Coil winding op ened. 1. Repl [...]

24 If you experience problems with the ice or water dispense, use the following charts along with the wiring diagram (section III, 3) to guide you through your troubleshooting. The following tables show the proper voltage readings for each operation. Water Dispensing Ice Dispensing in Continuous Mode Ice Dispensing in Portion Controlled Mode Layout[...]

25 4. Other PR O BLEM PO SSIBLE CA USE REMED Y [ 1] a) B in Con t rol Swit ch 1. Cont act s f us ed. 1. Replace. 2. O ut of posit i on. 2. Rein s t all. b) W at er Cont rol Relay 1 . Cont act s f us ed. 1. Repl ac e. c) T im er 1 . Def ect iv e. 1. R eplac e. [ 2] a) W at er Supply 1. W at er pres sur e t oo high. 1. I f pres s ure is cons ist ent [...]

26 V . Remov al and Replacement of Components IMPORT ANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORT ANT 1. The Polyol Ester (POE) oils used in R-404A units can absorb moisture quickly. Therefore it is important to prevent moisture from entering the sys- tem when replacing or servic[...]

27 4) Close the low-side valve and high-side valve on the service manifold. 5) Disconnect the vacuum pump, and attach a refrigerant service cylinder to the high-side line. Remember to loosen the connection, and purge the air from the hose. See the nameplate for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaim[...]

28 3. Removal and Replacement of Compressor IMPOR T ANT Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made. Note: When replacing a compressor with a defective winding, be sure to install the new start capacitor and start relay supplied w[...]

29 12) Braze the process, suction and discharge lines (do not change this order), while purging with nitrogen gas flowing at the pressure 3-4 PSIG. 13) Install the new filter drier. 14) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles. 15) Connect the terminals, and replace the terminal cover in its correct position. 16) Evacuate the [...]

30 5. Remo v al and Replacement of Thermostatic Expansion V alve IMPORT ANT Sometimes moisture in the refrigerant circuit exceeds the drier capacity and freezes up at the expansion valve. Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been mad[...]

31 14) Place the new expansion valve cover in position. 15) Replace the panels in their correct positions. 16) Plug in the dispenser and turn on the power supply. 6. Removal and Replacement of Pressure Switch IMPOR T ANT Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other r[...]

32 7. Remo v al and Replacement of Control W ater V alve 1) Unplug the icemaker. 2) Remove the panels. 3) Close the water supply line shut-off valve. 4) Disconnect the terminal from the control water valve. 5) Loosen the fitting nut on the control water valve inlets, and remove the control water valve. Do not lose the packings inside the fitting nu[...]

33 8. Remo v al and Replacement of Flush W ater V alve 1) Turn off the power supply. 2) Remove the panels. 3) Close the water supply line shut-off valve. 4) Remove the clamp and disconnect the hose from the flush water valve that attaches to the evaporator. Note: Water may still remain inside the evaporator. Be sure to drain the water into the drai[...]

34 9. Removal and Replacement of Float Switch W ARNING 1. Fragile, handle very carefully. 2. If the float switch works poorly because of scale or other foreign matter, install a filter or softener in the water supply line. 1) Unplug the dispenser and turn off the power supply. 2) Close the water supply line shut-off valve. 3) Remove the panels. 4) [...]

35 10. Removal and Replacement of Bin Control Switch Assembly 1) Turn off the power supply and unplug the dispenser. 2) Remove the top panel. 3) Remove the bin control switch from the storage bin cover. (Twist, then pull up.) 4) Cut the wire leads and remove switch. 5) Assemble the replacement switch, reversing the procedure used to remove the old [...]

36 11. Removal and Replacement of Storage Bin Assembly 1) Move the ice making switch to the “FLUSH” position. 2) Press the push button to dispense ice and remove all ice from the storage bin. 3) Turn off the power supply and unplug the dispenser. 4) Remove the panels. 5) Remove the storage bin cover. 6) Remove the agitator, drip ring, drip plat[...]

37 12. Removal and Replacement of Agitator and Drip Ring 1) Move the ice making switch to the “OFF” position. 2) Press the push button to dispense ice and remove all ice from the storage bin. 3) Turn off the power supply, and unplug the dispenser. 4) Remove the top panel. 5) Remove the storage bin cover. 6) Rotate the agitator counterclockwise [...]

38 13. Removal and Replacement of Evaporator Assembly 1) Move the ice making switch to the “OFF” position. 2) Press the push button to dispense ice and remove all ice from the storage bin. 3) Turn off the power supply, and unplug the dispenser. 4) Flush all water out of the system. 5) Remove the panels. 6) Remove the storage bin assembly. (See [...]

39 13) Disconnect the brazing-connections of the expansion valve and the copper tube - low side from the evaporator, using brazing equipment. 14) Braze the new evaporator with nitrogen gas flowing at a pressure of 3-4 PSIG. 15) Replace the drier. 16) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles. 17) Evacuate the system and charge [...]

40 28) Assemble the removed parts in the reverse order of which they were removed W ARNING Be careful not to scratch the surface of the O-ring, or it may cause water leaks. Handle the mechanical seal with care not to scratch nor to contaminate its contact surface. 29) Check for water leaks. W ARNING After assembling the extruding head, be sure to c[...]

41 Fig. 3 VI. Cleaning and Maintenance Instructions IMPORT ANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. 1. Preparing the Ice Dispenser for Long Storage IMPORT ANT When shutting off the ice dispenser for an extended time, drain out all water from the water line[...]

42 2. Cleaning Instructions W ARNING 1. HOSHIZAKI recommends cleaning this unit at least twice a year. More frequent cleaning, however, may be required in some existing water conditions. 2. To prevent injury to individuals and damage to the ice dispenser, do not use ammonia type cleaners. 3. Always wear liquid-proof gloves for safe handling of the [...]

43 Fig. 5 Fig. 4[...]

44 12) Replace the drip ring and agitator. 13) Move the ice making switch and then the power switch to the “ON” position. Place the storage bin cover in position, and start the automatic icemaking process. Run the ice dispenser until it stops automatically. 14) Move the ice making switch to the “FLUSH” position, and wait for flush process t[...]

45 [b] Sanitizing Procedure 1) Dilute approximately 1.5 fl. oz. of a 5.25% sodium hypochlorite solution (chlorine bleach) with 3 gal. of water. 2) Pour the sanitizing solution carefully into the reservoir through the opening in the center of the storage bin up to an overflow level. 3) Wait for 10 minutes to start the icemaking process. Move the ice[...]

46 2. Maintenance Instructions IMPORT ANT This ice dispenser must be maintained individually, referring to the instruction manual and labels provided with the ice dispenser. 1) Stainless Steel Exterior To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or d[...]