Hoshizaki DCM 300BAH(-OS) manual

Hoshizaki “A Superior Degr ee of Reliability” www .hoshizaki.com Models DCM-300BAH(-OS) Cubelet Icemaker/Dispenser Hoshizaki America, Inc. Number: 73189 Issued: 1-5-2012 SE RV ICE MA NU AL[...]

2 W ARNING Only quali ed ser vice technicians should inst all and ser vice the icemak er . T o obtain the name and phone number of y our local Hoshizaki Cer ti ed Ser vice Repr esentativ e, visit www .hoshizaki.com. No ser vice should be under tak en until the technician has thor oughly r ead this Ser vice Manual. F ailure t o ser vice and ma[...]

3 CONTENTS Impor tant Saf et y Inf or mation ................................................................................................. 5 I. Specications ...................................................................................................................... 7 A. Icemaker .....................................................[...]

4 IV . Ser vice Diagnosis ........................................................................................................... 21 A. Ice P roduction Chec k .................................................................................................. 21 B. Diagnostic P rocedur e ...........................................................[...]

5 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 , damage t o the appliance, or damage t o proper t y . W ARNING Indicates a hazar dous sit uation which could r esult in death or serious injury . NO TICE Indicates a sit uation which could r[...]

6 NO TICE •F ollo wtheinstructionsinthismanualcarefull ytor educetheriskofcostlyw at er damage. •Inareaswher ewat erdamageisaconcer n,installinacont ainedar eawitha oor drain. •Installtheicemak erinalocationthatsta ysa[...]

7 I. Specications A. Icemaker 1 . DCM-30 0B AH(-OS) Note: We r eserve the right to mak e changes in specications and design without prior notice. AC SUPPLY VOLTAGE 115-120/60/1 COMPRESSOR 115 V 6.0 RLA 29 LRA GEAR MOTOR 120 V 1.45 FLA 80 W FAN MOTOR 115 V 0.8 FLA 16 W AGITATING MOTOR 115 V 0.9 FLA 55 W DISPENSING MOTOR 115 V 0.9 FLA 55 W OTHE[...]

8 CONTROL DISPENSE MODE 4A1038-0 14 ICE OFF DRAIN PORTION CONTINUOUS II. General Inf ormation A. Construction 1 . Icemaker Stor age Bin Inlet W ater V alv e Reservoir Contr ol Bo x Air -Cooled Condenser Spout Co v er Ev aporat or Assembl y Compr essor Dispense Motor Agit ating Motor Agit ator Ice Dispense A uger Dispense W ater V alv e Gear Motor S[...]

9 2. Icemaking Unit Cut ter Seal Bolts and Washer s Gear Motor Spline Coupling O-Ring Mechanical Seal Extruding Head and Upper Bearing A uger Ev aporat or Housing and Low er Bearing He x Bolt and Washer Sock et Head Cap Scre w and Split Lock W asher Sock et Head Cap Scre w and Split Lock W asher[...]

10 B. Sequence of Operation 1 . Sequence Cycles and Shutdo wn The steps in the sequence ar e as outlined below . When pow er is supplied, pow er s witch is in the "ON" position, saf ety switch is eng aged, and the control s witch is in the "ICE" position, CB"PO WER" LED turns on. The "POWER" LED indicat es[...]

11 2. Sequence Flow Chart Legend: BC -bin control CB -control boar d Comp -compressor DCT - drain cy cle timer (1 2-hr. timer) DV -drain v al ve D V T- drain v alv e timer (20-min. timer) FM -fan mot or FT -ll timer (90-sec. low wat er saf ety timer) GM -gear motor LF/S -lower oatswitch UF/S -upperoats witch WV -inlet wat er va[...]

12 C. Control Boar d • A Hoshizaki e x clusive contr ol board is emplo yed in Hoshizaki icemak er s. • All models are pr e-test ed and f actor y adjust ed. • F or a contr ol boar d chec k pr ocedur e, see "IV .C . Contr ol Boar d Chec k P rocedur e." NO TICE • Thecontrolboar disfragile; handleverycareful[...]

13 • "PO WER" LED (green) (lights when 1 0.5V AC is supplied to K4 connect or pins #1 & #2) • "FLUSH" (drain) LED (X5 Rela y) K2 Connect or Pin #8 1 2-hr . Drain Timer K3 Connect or Pin #3 Contr ol S witch "DRAIN" P osition • "COMP" LED (X2 Rela y) X2 Rela y T er minals (1 15V AC) • "GM"[...]

14 Control Boar d P ar t Number 2A2649-0 1 b) DCM-30 0B AH-OS • K5 Connector #1, 2, 3 Ice Dispense Mode Switch, P or tion Operation (5VDC) #4, 5, 6 Ice Dispense Mode Switch, C ontinuous Operation (5VDC) #7 , 8, 9 W ater Dispense Sensor (5VDC) • "FLUSH" (drain) LED (X6 Rela y) K2 Connect or Pin #1 0 1 2-hr . Drain Timer K3 Connect or P[...]

15 2. LED Lights and Components The "PO WER" LED indicat es contr ol v oltage and will remain on unless a contr ol v oltage prob lem occurs . For fur ther details , see "II.B. Sequence of Operation." Icemaking Cyc le (Relay) LED Energized Components Time LEDs are On F requency LEDs ar e On Fill - WV N/A N/A Ice P urge (X1) GM GM[...]

16 3. Dispense Mode Switc h The dispense mode s witch has 2 positions , "CONTINUOUS" and "POR TION." a) CONTINUOUS When the dispense mode s witch is in the "CONTINUOUS" position, ice dispenses continuousl y f or a maximum of 60 seconds per activ ation. b) POR TION When the dispense mode s witch is in the "POR TION[...]

17 III. T echnical Infor mation A. W at er Cir cuit and R efr igeration Cir cuit Inlet W at er Va l v e Dispense W at er V alv e Drain Va l v e Float Switch W at er Le v el T o Drain Evapor ator Spout Expansion Va l v e Gear Motor Over ow Reservoir W at er Supply Drier Condenser F an Motor High-P ressure S witch Access Va l v e Access Va l v e C[...]

18 * B. W iring Diagrams 1 . DCM-30 0B AH * High-P ressur e S witch Cut-out 41 2± 21 PSIG Cut-in 327±21 PSIG 0[...]

19 2. DCM-30 0BAH-OS * High-P ressur e S witch Cut-out 41 2± 21 PSIG Cut-in 327±21 PSIG 0 *[...]

20 C. P erf ormance Data 1 . DCM-30 0B AH(-OS) APPROXIMATE Ambient ICE PRODUCTION Temp. (°F) PER 24 HR. 70 321 146 307 139 291 132 80 277 125 263 119 249 113 90 237 107 232 105 214 97 lbs./day kg/da y 100 203 92 193 87 181 82 APPROXIMATE ELECTRIC 70 653 -- 654 -- 655 -- CONSUMPTION 80 656 -- 658 -- 659 -- 90 660 -- 661 -- 666 -- watts 100 671 -- 6[...]

21 IV . Service Diagnosis W ARNING • Thisicemakershouldbediagnosedandr epairedonl yb yquali edser vice personnel t o reduce the risk of death, electr ic shoc k, serious injur y , or re . •Riskofelectricshock. Useextr emecautionandex ercisesaf eelectr icalpractices . ?[...]

22 7) Startup – Mov e the power s witch to the "ON" position, then mo v e the control s witch to the "ICE" position to st ar t the aut omatic icemaking process . Diagnosis: Check that CB "PO WER" LED is on. If not, check f or proper po wer suppl y voltage (1 1 5V AC) input t o CT . If 1 1 5V A C is not pr esent, chec[...]

23 9) Ice Pur g e Cy c le – "GM" LED is on. GM and GMPR ener gize . 60-sec. ice purge timer star ts. GM runs for 60 sec. to clear an y ice from the e vaporat or . Note: GM cannot energiz e unless UF/S is closed, WCR is ener gized, and WCR t er minals #4 (O wir e) and #6(GYwire) ar e closed. Diagnosis : If "GM" LED is of [...]

24 1 2) Drain Cy c le – "FLUSH" (dr ain) LED is on. The icemak er drains the e vapor at or and reservoir once e very 1 2 hr . A manual drain is pr ovided when cleaning the icemak er by moving the contr ol switch fr om the "ICE" position to the "DRAIN" position. a) A ut omatic Dr ain Cy c le: A drain cy cle occurs onc[...]

25 if def ectiv e. If 24V AC is pr esent, check f or 24V AC at GMPR t er minal #2 (P wire) to a neutr al (LBU wir e). If 24V A C is not pr esent, chec k GMPR continuity bet ween terminals #2 (P wire) and #6 (LB U wir e). If open, replace GMPR. Next, chec k for 24V A C at D V . If 24V A C is pr esent and D V does not ener gize , check D V solenoid c[...]

26 C. Control Boar d Check Bef or e r eplacing CB that does not sho w a visib le def ect and that y ou suspect is bad, conduct the f ollo wing CB chec k. This procedur e will help y ou v erify your diagnosis . Bef or e pr oceeding , chec k f or proper v oltage per unit nameplat e. Check that the 24V A C 1A fuse, 1 0.5V A C 0.5A CT fuse ar e good, a[...]

27 •IcemakingContr olCircuit:  Theicemakingcontrolcir cuitconsistsof WCR,CS ,and BC . The icemaking control cir cuit activ ates once UF/S closes. Once CB reads a closed circuit thr ough WCR, CS , and BC , CB then star ts the 60-sec. ice purge c y cle (GM operation). Once UF/S closes, WCR energiz es , closing[...]

28 b) Opti-Ser v e Model – "ICE" and "AM" LEDs ar e on: (1) "CONTINUOUS" Mode: Bef or e eng aging the ice dispense Opti-Ser v e sensor , check f or 5VDC from the locations giv en in the table belo w . If VDC is dif fer ent than in the tab le , r eplace CB . If VDC is correct, eng age the Opti-Ser v e sensor and con?[...]

29 • W at erDispenseS witch/W aterDispenseSensor a) P ush But t on Model: The wat er dispense but ton and DispWV ar e not associated with CB. Eng age the wat er dispense but ton, then chec k for 24V AC at DispWV . If 24V AC is present and no w ater is dispensed, chec k f or water suppl y line shut-of f v al v e closed, clogged w[...]

30 8) Drain Cy cle – "FLUSH" (dr ain) LED is on: 1 2-hr . DCT terminates or CS is mo v ed to "DRAIN" position. 1 50-sec. shutdown sequence st ar ts. 90 seconds later , Comp de-energiz es and Comp LED tur ns of f . 60 seconds af t er Comp de-ener gizes, GM de-energiz es and GM LED tur ns of f . Drain cy cle star ts. "FLUSH[...]

31 D . Bin Contr ol Check 1) Remo ve the fr ont and t op panels. 2) Remo ve the st orage bin co ver . If necessar y , dispense ice so that the BC actuator is not engaged or r emov e the ice manuall y . W ARNING! Care should be tak en to a v oid the agitat or dur ing BC testing. 3) Mov e the control s witch to the "OFF" position. 4) Mov e [...]

32 E. Float S witch Chec k and Cleaning 1 . Float Switch Chec k 1) Remo ve the fr ont panel, then mak e sur e the pow er s witch is in the "ON" position. 2) Mov e the control s witch to the "DRAIN" position. 3) Engage the saf et y s witch and allow the e vaporat or and reser v oir t o drain. 4) Disengage the saf et y s witch, th[...]

33 2. Float Switc h Cleaning Depending on local wat er conditions, scale ma y b uild up on F/S . Scale on F/S can cause inconsistent oper ation of UF/S and LF/S . In this case, both UF/S and LF/S should be cleaned and check ed. 1) Mov e the control s witch to the "OFF" position. 2) Remo ve the fr ont panel, then mo v e the pow er s witch [...]

34 F . Diagnostic Charts Bef or e consulting the diagnostic char ts, chec k for corr ect installation, proper v oltage per unit nameplate , and adequate wat er pressur e (1 0 to 1 1 3 PSIG). Check CB using the st eps in "IV .C . Control Boar d Check." 1 . No Ice Production Startup 1. P ower Suppl y a) Of f, b lown fuse , or tripped break [...]

35 Ice Pur ge Cyc le 1. Contr ol Boar d a) No power t o gear motor . 2. Gear Motor a) External prot ect or (gear motor o verload) open. b) Internal prot ect or open. c) Motor winding open. d) Mechanical f ailure . 3. Coupling a) Def ectiv e. F reeze Cyc le 1. Contr ol Boar d a) Def ectiv e. 2. Compressor a) External prot ect or open. b) Motor windi[...]

36 2. Ice/W at er Dispense Ice Dispense Push But ton 1. P ower Suppl y a) See "Star tup ." 2. Control Boar d a) Ice dispense s witch cir cuit open or no pow er . b) No power t o ice dispense solenoid, ice dispense motor , or agitating motor . 3. Ice Dispense Switch a) Def ectiv e. 4. Dispense Mode Switch a) Def ectiv e (open). 5. Ice Disp[...]

37 3. Opti-Ser v e (OS) Sensor s Be sure t o check all it ems in section "IV .F .2. Ice/W ater Dispense" prior to using this char t. Use the f ollo wing char ts along with the wiring diagram to tr oubleshoot the OS sensor s . Ice Sensor 1. OS Sensor a) Dir ty . b) Def ectiv e. See char t 3a and 3b . 2. Control Boar d a) No pow er t o infr[...]

38 V . R emo v al and Replacement of Components W ARNING • Thisicemakershouldbediagnosedandr epairedonl yb yquali edser vice personnel t o reduce the risk of death, electr ic shoc k, serious injur y , or re . •Mov ethepowers witchtothe"OFF"positionandturnof f?[...]

39 1 . Refriger ant R eco v ery This icemaker is pr ovided with r efrigerant access v alv es. Using proper r efr igerant practices , r ecov er the refrigerant fr om the ser vice v alv es and st or e it in an appr ov ed container . Do not discharge the r efrigerant int o the atmospher e. 2. Brazing W ARNING •R-404Aitselfisnot amm[...]

40 4) Close the low -side val v e and high-side val v e on the g auge manif old. 5) Disconnect the gauge manif old hose from the v acuum pump and at tach it t o a refrigerant service cylinder . Remember t o loosen the connection and purge the air fr om the hose. See the rating label inside the icemak er f or the requir ed r efrigerant charge . Hosh[...]

41 F ig. 2 Extruding Head and Upper Bearing Ev aporat or Allen Head C ap Scre w with W asher Allen Head C ap Scre w Housing and Low er Bearing Gear Motor Spline Coupling O-Ring Mechanical Seal A uger Cut ter He x Head Bolt with W asher W asher Spout B Spout A P ower S witch Contr ol S witch Dispense Mode S witch Evapor at or Assembl y Ev apor at or[...]

42 1 . Upper Bearing W ear Check T o ensure that the bearing inside the e xtruding head does not ex ceed the wear t olerance of .02", f ollo w the instructions below . See Fig . 3. 1) Mov e the control s witch to the "OFF" position, then turn off the po wer supply . Remo v e the front and t op panels, then mov e the power s witch to [...]

43 9) Mov e the power s witch to the "ON" position, then r eplace the panels in their corr ect positions. 1 0) T ur n on the power suppl y , then mov e the control s witch to the "ICE" position t o star t the automatic icemaking pr ocess. 3. Remo v al and R eplacement of A ug er 1) Mov e the control s witch to the "DRAIN&qu[...]

44 3) Remo ve the apr on panel, then r emov e the lef t side panel. 4) Reco ver the r efrigerant and st ore it in an appr ov ed container . 5) Remo ve the fr ont co v er of the st orage bin. Remo ve spout B , then r emov e spout A. See F ig . 2. 6) Remo ve the allen head cap scr e ws securing the extruding head. Using the cut t er , lift out the au[...]

45 5. Remo v al and R eplacement of Mechanical Seal and Lo w er Housing 5a. Mechanical Seal 1) Mov e the control s witch to the "DRAIN" position and drain all of the w at er fr om the e v aporator . 2) Af ter the wat er has stopped draining , mov e the contr ol s witch to the "OFF" position, then tur n of f the power suppl y . R[...]

46 6. Remo v al and R eplacement of Gear Mot or 1) Mov e the control s witch to the "DRAIN" position and drain all of the w at er fr om the e v aporator . 2) Af ter the wat er has stopped draining , mov e the contr ol s witch to the "OFF" position, then tur n of f the power suppl y . Remo v e the fr ont and t op panels , then mo[...]

47 7 . Dispense A uger and Agitat or 1) Mov e the control s witch to the "OFF" position, then turn off the po wer supply . Remo v e the front and t op panels, then mov e the power s witch to the "OFF" position. 2) Remo ve the fr ont co v er of the st orage bin. 3) Remo ve the thumbscr e ws fr om the v er tical plane, then loosen[...]

48 VI. Cleaning and Maintenance This icemaker m ust be cleaned and maintained in accor dance with the instr uction manual and labels pr o vided with the icemak er . Consult with your local distrib ut or about cleaning and maintenance service. T o obtain the name and phone number of your local distrib ut or , visit www .hoshizaki.com or call Hoshiza[...]

49 A. Cleaning and Sanitizing Instructions Hoshizaki recommends cleaning and sanitizing this icemak er at least t wice a year . More fr equent cleaning and sanitizing, ho we ver , may be r equired in some e xisting water conditions. W ARNING • T opre ventinjur yt oindividualsanddamaget otheicemak er ,donotus[...]

50 9)Inbadorse v erewat erconditions,cleanthe oats witchassembl yasdescribedbelow .  Otherwise, contin ue t o st ep 1 0. a. Remov ethe oats witchassemb l yfr omther eser v oircover . b .  Wipedownthe oats witchassemb l ywiththecleaningsolu[...]

51 9) Mov e the control s witch to the "ICE" position. Open the icemaker w at er suppl y line shut-of f val ve t o suppl y wat er to the r eser v oir . 1 0) Af ter the gear mot or star ts , mov e the control s witch to the "DRAIN" position. Allow the wat er sy st em to dr ain f or 5minutes . 1 1) Mov e the control s witch to [...]

52 8) Remo ve the spout co v er , ice dispense spout, and wat er dispense nozzle. See Fig . 7 . 9) Immerse the agit at or , dispense auger , and par ts r emov ed in steps 5 thr ough 8 in the cleaning solution and then in the sanitizing solution f or 1 5 minut es each. Rinse the par ts thoroughl y with clean wat er . On Opti-Ser ve models (-OS), wip[...]

53 B. Maintenance The maintenance schedule belo w is a guideline. More fr equent maintenance ma y be requir eddependingonwat erquality ,theicemak er'sen vir onment,andlocalsanitation regulations . W ARNING •Onlyquali edser vicetechniciansshouldservicethisicemaker . •Mov ethe[...]

54 C. Pr eparing the Icemak er f or Per iods of Non-Use NO TICE When st or ing the icemak er f or an ext ended time or in sub-freezing temper atur es , f ollo w the instructions below t o pr e v ent damage. When the icemak er is not used for t wo or thr ee day s under nor mal conditions, it is suf ficient t o onl y mov e the control s witch to the [...]

55 VII. Disposal This icemaker cont ains r efrigerant and must be disposed of in accor dance with applicable national, st at e , and local codes and r egulations. Refrigerant m ust be reco ver ed b y pr operly cer ti ed ser vice personnel.[...]