Hoshizaki 73168 manual

Hoshizaki “A Superior Degr ee of Reliability” www .hoshizaki.com Model Refrigerated Prep Table with Raised Rail Commercial Kitchen Equipment Hoshizaki America, Inc. Number: 73168 Issued: 8-12-2009 Revised: 5-11-2011 SE RV ICE MA NU AL[...]

2 IMPOR T ANT Only quali ed ser vice technicians should inst all, ser vice , and maintain the unit. No ser vice or maint enance should be under tak en until the t echnician has thoroughl y read this Ser vice Manual. F ailure t o ser vice and maintain the equipment in accordance with this man ual ma y adver sely af fect saf et y , perf ormance, c[...]

3 IMPOR T ANT This manual should be r ead car efull y bef ore the unit is ser viced or maintenance oper ations ar e perf or med. Only quali ed ser vice technicians should install, service, and maintain the unit. Read the warnings contained in this booklet carefull y as they giv e impor tant inf or mation reg arding saf et y . Please ret ain this[...]

4 III. Ser vice Diagnosis ........................................................................................................... 25 A. Alar m Signals .............................................................................................................. 25 1 . High T emperatur e Alar m (E1) ..............................................[...]

5 5. Door/Drawer Gask ets ............................................................................................ 59 6. Shelv es (if applicab le) ............................................................................................ 59 7 . Drawer s (if applicable) ..........................................................................[...]

6 Impor tant Safety Inf ormation Throughout this man ual, notices appear t o bring your at tention t o situations which could result in death, serious injur y , or damage to the unit. W ARNING Indicates a hazardous sit uation which could result in death or serious injury . C A UTION Indicates a sit uation which could result in dama ge to the unit. [...]

7 I. Specications A. Nameplate Ratings Model A C Supply V oltage Amperes Design Pr essur e (PSIG) Refr igerant HI LO 404A HPR46A(-D) 1 1 5/60/1 7. 6 450 250 28.5 oz. HPR72A See Unit Nameplate 36.1 oz. HPR72A -D 1 3.6 HPR1 00A(-D) TBD TBD B. Dimensions Model Inter ior V olume Cu. Ft. Rail Capacity QTY of 1/6 Sized Pans Exter ior Height (HE) mm (i[...]

8 II. General Inf ormation A. Construction This Hoshizaki unit f eatur es a car tridge-t ype refrigeration s ystem that can be r emov ed (e x cluding the rail e vaporat or). C abinet Air Duct Refrigeration C ar tridge C abinet Evapor at or Assembl y C abinet Ther mist or C abinet Evapor at or F an Motor s C abinet Interior Side P anel Defrost Therm[...]

9 B. Sequence of Operation The steps in the sequence ar e as outlined below . 1 . Startup Whenthepo wers witchisinthe"ON"position,thecabinett emperatur eisdispla yed andcabinetcoolingbegins.  Whenthepow ers witchisinthe"ON"positionandtherail?[...]

10 (3) Both CT h and R Th r each 3.6 ° F (2 ° C) belo w setpoint C abFM and PH continue . RailFM continues when rail cooling s witch is in the "NORMAL"positionandperF9set tingwheninthe"LO W"position. F ordetails, see"II.D .4.a)SwitchSet tings."C omp,C onFM,and?[...]

11 a) Cabinet Defrost: P ow er S witch "ON," R ail Cooling Switc h "OFF" CLL V continues , C abFM, Comp , C onFM, and PH de-ener gize . DH energiz es and warms DTh to 49°F (9.4°C) (or the 1 00-minute defr ost ter mination timer e xpires or DTst warms to 1 20°F±5°F (49°C±3°C)). When DTh r eaches 49°F (9.4°C), DH de-ener[...]

12 C. Sequence of Operation Charts 1 . Cabinet Cooling Legend: CabFM -cabinet f an motor Comp -compressor ConFM -condenser f an motor CLL V -cabinet liquid line v alv e CTh -cabinet thermistor DH -defrost heat er DT -defrost timer DTh -defrost thermistor DTst -defrost thermostat PH -perimeter heater CabFM energiz ed CLL V energiz ed PH energiz ed C[...]

13 2. Cabinet and Rail Cooling Legend: C -cabinet cooling CabFM -cabinet f an motor Comp -compressor ConFM -condenser f an motor CLL V -cabinet liquid line v alv e CTh -cabinet thermistor DT -detrost timer DH -defrost heat er DTh -defrost thermistor DTst -defrost thermostat PH -perimeter heater R -rail cooling RailFM -rail f an mot or RLL V -rail l[...]

14 2. Cabinet and Rail Cooling (continued) 4. Cabinet Defrost DTh in control •6‑hourDTe xpires ,thenr esets •1 00‑minutedefr ostterminationtimerstarts T o 2 previous page P ow er S witch "ON," Rail Cooling S witch "NORMAL" or "L O W" P osition (continued) DTh reaches 49°F (9.4?[...]

15 D . Contr ol Board • AHoshizakie x clusivesolid‑st at econtr olboar disemplo yedinallHoshizaki HPR46A(-D), HPR72A(-D), and HPR1 00A(-D) units. • Allmodelsarepr etest edandf actor yset. C A UTION 1 . The control boar d is fragile; handle very carefull y . 2. The contr ol boar d contai[...]

16 F ront Displa y/Change Rail Setpoint "UP"But t on "DO WN"But ton "SER VICEUSEONL Y"Butt on "MANU ALDEFR OST"b utt on LED on f or Negativ e V alues Cabinet T emperatur e, Alarm Display , and Ser vice Menu Rail T emperature , Alarm Display , and Ser vice Menu Displa y/Change Cabinet Setp[...]

17 3. Feat ures a) LED Display and Service Lock-Out This control boar d uses t win LED display s t o sho w s y stem det ails and diagnostic inf ormation. F or control boar d volt age pr ot ection, a 3A 1 25V fuse is incor porated into the contr ol board cir cuitr y . A ser vice jumper is also provided t o prot ect ag ainst unw anted changes t o the[...]

18 4. Controls and A djustments The cabinet and rail t emperatur es are updat ed e ver y 30 seconds . The control boar d is supplied with a ser vice jumper on the K1 51 connector . Only the t emperatur e setpoint andthetemper atur escale("F5")ma ybeadjustedwiththisconnect orinplace.  T oview or[...]

19 Section T emperat ure Setpoint Range Default C abinet 21 to 53°F (-6 to +1 2°C) 37°F (3°C) Rail -1 3 to +53°F (-25 to +1 2°C) 33°F (1°C) c) T emperat ur e Setpoint The temper atur e setpoint is the t emperatur e set ting at which the compr essor tur ns on. The f act or y def ault temperatur e setpoints are 37° (3°C) f or the cabinet an[...]

20 f) T emperat ure Cor rection F act or In cases where ther e is a discrepancy bet ween the actual cabinet or r ail t emperatur e and the displa y ed t emperatur e, a temper atur e corr ection f actor is used t o corr ect the displa y ed t emperatur e. W ARNING This unit has been f act or y t est ed with the def ault set tings list ed. A v oid usi[...]

21 5. Ser vice Menu Theser vicemenu("F0"t o"F9")maybeusedt ochangeset tings,acquir ediagnostic inf ormation, and to vie w alar m hist ory . T oaccessthe"F0"through"F9"ser vicemenuselections ,youmustr stdisconnectthe ser vic[...]

22 Service Menu Item and Details Set ting Range Fact or y Default Cabinet Rail Cabinet Rail F0 Defrost Int er val • Thecabinetusesatimeinitiated heated defr ost. • Thechangeinthedefrost interval set ting will take ef f ect immediatel y . The ne xt defr ost will tak e place af ter the newl y set time interv[...]

23 6. Alarm Signals In the e v ent of operation outside of nor mal paramet er s , the contr ol board identi es the issue with an alar m signal. The alar m signal and temper atur e are displa yed in 1 -second intervals . Forservicecorrections ,see"III.A.  Alar mSignals." Alarm Signals E1 High T emperature Alarm E2 L[...]

24 E. Thermist or Check Ther mist or s (semiconduct or s) ar e used f or temperatur e contr ol in the cabinet and rail ar eas , defr ost t er mination, and f or monitoring condenser temper ature (clogged lt er). The resistance v ar ies depending on t emperatur e. No adjustment is required. If necessar y , check f or resist ance bet ween ther mis[...]

25 III. Service Diagnosis W ARNING 1 . This unit should be disassembled or r epaired onl y b y a quali ed service technician t o reduce the risk of injur y , electr ic shoc k, or r e. 2. Do not make any alt erations to the unit. This could cause wat er leak, electric shock, or r e. 3. T o help reduce the risk of electric shock, do not t ou[...]

26 Alarm Signal Pr iority Pr oblem Reset, Corr ections, and A djustments E7 6 High Condenser T emperature Alarm (clogged lt er) Condenser t emperatur e is outside of nor mal operating t emperature . 1 40°F (60°C) T ur n the pow er of f, then bac k on. Condenser and/or air  lter dirt y . F an motor not turning. P ossible restriction in refri[...]

27 1 . High T emperat ur e Alarm (E1) If the cabinet or rail t emperatur e ex ceeds the setpoint t emperatur e by 1 8°F (1 0°C) or moref ormorethanxhour s,"E1"isdispla y ed.  Thedefaultv alueofxis"2"(2hours).  Thev alueofxcanbechangedunder"F3&qu[...]

28 2. Low T emper at ur e Alarm (E2) If the cabinet or rail t emperatur e drops belo w the setpoint temper atur e b y 9°F (5°C) or moref ormorethanyhour s,"E2"isdispla y ed.  Thedefaultv alueofyis"1"(1hour).  The v alueofycanbechangedunder"F4&qu[...]

29 3. Cabinet Defrost Alarm (E3) Once the defrost t er mination temper atur e is r eached, the signal fr om the defr ost ther mist or should t erminate the defrost. If the defrost thermistor does not t er minate the defrostwithin1 00minut es(1hourand40minut es),"E3"isdisplay ed.  W hen"E3"?[...]

30 4. High Condenser T emperat ure Alarm (c logged lt er) (E7) The unit is equipped with a condenser air lt er to pr ot ect the condenser from dirt, grease , etc. The condenser air  lt er pr omot es clean condenser surf aces and ef ficient oper ation and should be check ed t wice monthly and cleaned when necessar y . The unit is also equip[...]

31 5. Defrost Thermist or (cabinet) Malfunction Alarm (E8) Ifthecontrolboar ddetectsanopendefr ostthermistor ,"E8"isdispla y ed.  W henthe control boar d detects a shor ted defr ost ther mistor , a 1 0-minute dela y timer begins. Af t er the1 0‑minut edelaytimere xpires ,"E8&[...]

32 6. Condenser Thermistor Malfunction Alarm (E9) Ifthecontrolboar ddetectsanopencondenserthermistor ,"E9"isdispla y ed.  W henthe control boar d detects a shor ted condenser thermistor , a 1 0-minute dela y timer begins. Af terthe1 0‑minutedela ytimerexpir es,"E9"[...]

33 Pr oblem P ossible Cause Remed y [1] The unit will not star t. a) P ower Suppl y 1. Unplugged, of f, blo wn fuse, or tripped or def ectiv e circuit break er . 1. T ur n on, replace , or check and reset. Call electrician if break er tr ips repeat edly . 2. Loose connection. 2. T ight en. 3. Not within specications. 3. Ref er to nameplat e and [...]

34 Pr oblem P ossible Cause Remed y [3] Compr essor will not star t or stops oper ating. (continued) f) V oltage 1. T oo low . 1. Call electrician. 2. T oo high. 2. Call electrician. g) High P ressur e S witch 1. Restrict ed air  ow t o condenser . 1. Mov e unit or increase v entilation. 2. Condenser air  lter and/or condenser clogged. 2. Cle[...]

35 Pr oblem P ossible Cause Remed y [1] C abinet temper ature t oo high. (continued) g) Defrost 1. Defrost time insuf ficient to r emov e frost. Operation in humid conditions. 1. See"4. CabinetDefr ost." 2. Incomplete defr ost. 2. See"4. CabinetDefr ost." h) Air F ilter or C ondenser 1. Clogged, dir t y . 1. Cl[...]

36 3. Rail Cooling Pr oblem P ossible Cause Remed y [1] Rail t emperatur e too high. a) W ar m Food 1. W ar m food r ecently placed in rail ar ea. 1. P re-cool f ood or allow time f or unit to r etur n to setpoint temper ature . b) Rail P ans/Dividers 1. Missing , not in place. 1. Replace . P ans must cov er entire r ail f or pr oper cooling. c) Ou[...]

37 4. Cabinet Defrost Pr oblem P ossible Cause Remed y [1] C abinet f an mot ors on. a) Cabinet F an Rela y 1. Bad contacts (closed). 1. Chec k f or continuity and replace . b) Contr ol Boar d 1. Def ectiv e. 1. R eplace. [2] Ev aporat or does not defrost completel y . a) Defrost Thermistor 1. Def ective. 1. See"II.E.  Ther mistor Che[...]

38 5. Other Pr oblem P ossible Cause Remed y [1] Condensat e wat er ov ero w . a) C abinet Cont ents 1. Loading large v olumes of warm, moist, uncov ered product. 1. P re-cool f ood. Cov er product with plastic wr ap . b) Location of Unit 1. Unit located near high humidity source such as fr y er , steamer , etc. 1. Relocat e. c) Seals 1. P oor s[...]

39 IV . R emo v al and Replacement of Components W ARNING 1 . This unit should be diagnosed and repair ed only b y quali ed ser vice personnel t o reduce the risk of death, electr ic shoc k, serious injur y , or re . 2. Movethepo wers witcht othe"OFF"positionandunplugtheunitbef or e ser vici[...]

40 2. Brazing W ARNING 1 . R-404A itself is not  ammab le at atmospheric pressur e and t emperatur es up to 1 76°F (80°C). 2. R-404A itself is not explosiv e or poisonous. How e ver , when exposed t o high temper atur es (open  ames), these refrigerants can be decomposed to f or m h y dr ouoric acid and carbonyl uoride both of which a[...]

41 3) Allowthev acuumpumptopulldownt oa29.9"Hgvacuum. Evacuatingperioddepends on pump capacity . 4) Close both gauge manif old v al v es. 5) T ur n of f the v acuum pump. Disconnect the v acuum pump hose and at tach it to a refrigerant service cylinder . Remember t o loosen the connection, and pu[...]

42 B. Remo val and R eplacement of Refr igeration S yst em Car tridge C A UTION The refrigeration s yst em car tr idge should not be r emo v ed until the r efrigerant has been properl y r ecov ered or the r efrigeration s y st em has been pr operly pumped down. F or r efrigeration sy stem r epair s, the r efr igerant r ecov er y procedur emust?[...]

43 1 3) Slide the refrigeration car tridge forw ar d. Suppor t the e vaporat or as it clears the e v aporator case . See Fig . 2. C A UTION 1 . Be careful when handling the cabinet e vapor at or assemb l y . This assemb l y includes a defrost heat er sheathed in a glass tube. This sheathing can be easily damaged and ma y also cause cuts if brok en.[...]

44 2. Refr igeration S ystem P ump-Down P r ocedure 1)Remo vethefr ontpanel. Mov ethepow ers witchtothe"OFF"position,thenunplugthe unit. 2) Remo ve the lef t side panel. 3) Connect the g auge manifold hoses t o the receiv er ser vice v alv e (high-side) and the rail low -side access val v e.[...]

45 1 6) Once the repair is made , r eplace the refrigeration car tridge back int o its correct position. Suppor t the cabinet e vaporat or as it enter s the cabinet e vaporat or case. 1 7) Reconnect the rail side r efr igerant tubes . Use a backup wr ench and tight en the  t tings 1/6 tur n be y ond full y seat ed. Use a backup wr ench when tigh[...]

46 F ig. 2 Refrigeration C ar tr idge C abinet F an Motor s C abinet Ther mist or Defrost Thermistor Defrost Thermostat Defrost Heat er Rail Thermistor C abinet Evapor at or F an Motor Shr oud Ev aporat or C ase[...]

47 C. Remo val and R eplacement of Compressor C A UTION 1 . Alw a ys install a ne w dr ier e ver y time the sealed r efrigeration sy stem is opened. 2. Do not replace the drier until af t er all other r epair or r eplacement has been made. Install the ne w drier with the arro w on the drier in the direction of the refrigerant  ow . 3. W hen braz[...]

48 1 5) Replace the panels in their corr ect positions . 1 6)Plugintheunit,thenmov ethepo wers witchtothe"ON"positiont ostar ttheunit's cooling process . D . R emov al and R eplacement of Cabinet Ev apor ator C A UTION 1 . Alw a ys install a ne w dr ier e ver y time the sealed r e[...]

49 8) Braz e the  t tings while purging with nitrogen g as o wing at a pressure of 3 t o 4 PSIG. 9) Replace the r emov ed e vaporat or par ts in their correct positions. 1 0)Oncether epairiscomplet e,r etur ntost ep1 5in"IV .B.1 . R ecov er yP rocedur e"for refrigeration s yst em car tr i[...]

50 F . R emo val and R eplacement of Liquid Line V alve C A UTION 1 . Alw a ys install a ne w dr ier e ver y time the sealed r efrigeration sy stem is opened. 2. Do not replace the drier until af t er all other r epair or r eplacement has been made. Install the ne w drier with the arro w on the drier in the direction of the refrigerant  ow . 3. [...]

51 G. Remo val and R eplacement of Condenser C A UTION 1 . Alw a ys install a ne w dr ier e ver y time the sealed r efrigeration sy stem is opened. 2. Do not replace the drier until af t er all other r epair or r eplacement has been made. Install the ne w drier with the arro w on the drier in the direction of the refrigerant  ow . 3. W hen brazi[...]

52 H. Remo val and R eplacement of Thermist ors and Thermostat C A UTION 1 . The ther mist or s are fr agile; handle ver y car efull y . 2. Do not shor t en or cut the ther mist or leads . 1 . Cabinet Ther mist or 1)Remo vether efrigerations yst emcar tr idge. P erformsteps1thr ough1 6in"IV .B.2.  P ump?[...]

53 3. Defrost Ther mostat 1)Remo vether efrigerations yst emcar tr idge. P erformsteps1thr ough1 6in"IV .B.2.  P ump‑DownP r ocedur e."Oncether efr igerations yst emcar tr idgeisout,pr oceedt o step 2. 2) Disconnect the defrost thermostat wir es, then r emov e the d[...]

54 I. Remo val and R eplacement of Defrost Heat er C A UTION Be careful when handling both the old and ne w defrost heat er s. The heater s are sheathed in glass tubes and can possib ly cause cuts if br ok en. The heater will also be hot af ter a defr ost. Use glov es when handling . A v oid t ouching the glass directl y; hold the heater s b y the [...]

55 J . Remo val and R eplacement of Fan Mot ors 1 . Cabinet F an Mot or C A UTION Be careful when handling the e v aporat or shroud assembl y . This assembl y includes a defrost heat er sheathed in a glass tube. This sheathing can be easily damaged and ma y also cause cuts if brok en. Heater will also be hot af t er a defrost. Use glov es when hand[...]

56 2. Condenser Fan Mot or 1)Openthefrontpanel. Mov ethepowers witchtothe"OFF"position,thenunplugthe unit. 2) Remo ve the lef t side panel. 3) Disconnect the f an mot or wir es . 4) Remo ve the condenser f an motor assemb l y bolts, then r emov e the condenser f an motor assemb ly . See Fig [...]

57 K. Remo val and R eplacement of Door Gasket Remo ve the old g ask et b y pulling it dir ectl y out of the vinyl g asket r etainer . Thoroughl y clean the gask et area with mild soap and w at er prior to installing the ne w gask et. The new g asket should be installed at the corners r st, then wor king t o war d the center at the top , bot tom[...]

58 V . Cleaning and Maint enance Instructions A. Cleaning W ARNING 1 . Bef or ecleaningtheunit,mov ethepowers witchtothe"OFF"positionand unplug the unit to pr ev ent electr ic shoc k b y une xpected entrance of w at er into the unit or injury by mo ving par ts. 2. Befor e cleaning the unit, mo v e[...]

59 2. Rail and Rail Cov er Spills and splashes should be wiped up promptl y to a v oid unpleasant odors. Wipe the interior of the rail and the r ail cov er regularly with a clean, damp sponge or cloth containing a neutral cleaner . Do not pour or spra y water int o the rail area. W ARNING 1 . Be sure t o suppor t the rail co ver when cleaning . Oth[...]

60 B. Maintenance 1 . Rail Condensat e P an The rail condensat e pan collects condensat e w at er fr om the rail. Empt y the pan as of ten as necessar y depending on conditions. Clean the pan at least once a month with a clean, damp sponge or cloth containing a neutral cleaner . 2. Air F ilter The plastic mesh air lt er (located behind the fr on[...]

61 C. Shutdown and Long St orage W ARNING 1 . When pr eparing the unit for long st orage, pr ev ent the doors/dra wers fr om closing to r educe the r isk of childr en get ting trapped. 2. T o reduce the risk of electric shock, do not t ouch the at tachment plug or s witches with damp hands . 3. T o unplug the unit, be sure t o pull the at tachment [...]

62 VI. T echnical Information A. Refr ig er ation Cir cuit 1 . HPR46A(-D), HPR72A(-D), HPR1 0 0A(-D) Note: The number of rail f ans varies bet ween models. F ront Cabinet Expansion Va l v e C abinet F ans Rail F ans Rail Ev aporat or Cabinet Ev aporat or C abinet Liquid Line Va l v e Rail Expansion V al v e Compr essor Compr essor A ccess V alve C [...]

63 B. W iring Diagr ams 1 . HPR46A(-D) *High Pr essure Switc h Cut-out 490±1 0 PSIG Cut-in 370±20 PSIG T ransformer Output 1 0V at 1 15V *[...]

64 2a. HPR72A(-D) Auxiliary Code U-5 and Earlier *High Pr essure Switc h Cut-out 490±1 0 PSIG Cut-in 370±20 PSIG T ransformer Output 1 0V at 1 15V *[...]

65 2b. HPR72A(-D) Auxiliary Code U-6 and Later T ransformer Output 1 0V at 1 15V * *High Pr essure Switc h Cut-out 490±1 0 PSIG Cut-in 370±20 PSIG[...]

66 3. HPR1 0 0A(-D) A W AITING D A T A[...]