Hoshizaki Ice Maker DCM 270BAH User Manual

Hoshizaki America, Inc.

Hoshizaki

Cubelet Icemaker/Dispenser

Models

DCM-270BAH

SERVICE MANUAL

“A Superior Degree

of Reliability”

www.hoshizaki.com

Number: 73100

Issued: 4-30-2002

Revised: 12-15-2003

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• 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

PAGE

I. SPECIFICATIONS........................................................................................................................... 4

1. DCM-270BAH (Air-cooled)......................................................................................................... 4

II. GENERALINFORMATION ............................................................................................................. 5

1. CONSTRUCTION ...................................................................................................................... 5

2. OPERATION - How it works ...................................................................................................... 6

III.TECHNICALINFORMATION ......................................................................................................... 7

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT .................................................................... 7

2. PERFORMANCE DATA ............................................................................................................ 8

3. WIRING DIAGRAM.................................................................................................................... 9

4. SEQUENCE OF ELECTRICAL CIRCUIT ................................................................................ 10

IV. SERVICE DIAGNOSIS ............................................................................................................... 21

1. NO ICE PRODUCTION ........................................................................................................... 21

2. LOW ICE PRODUCTION......................................................................................................... 23

3. FAULTY DISPENSER ............................................................................................................. 24

4. OTHERS .................................................................................................................................. 25

V. REMOVAL AND REPLACEMENT OF COMPONENTS ............................................................... 26

1. SERVICE FOR REFRIGERANT LINES.................................................................................... 26

[a]REFRIGERANTRECOVERY............................................................................................ 26

[b] EVACUATION AND RECHARGE [R-404A] ...................................................................... 26

2. BRAZING.................................................................................................................................. 27

3. REMOVAL AND REPLACEMENT OF COMPRESSOR ........................................................... 28

4. REMOVAL AND REPLACEMENT OF DRIER .......................................................................... 29

5. REMOVAL AND REPLACEMENT OF THERMOSTATIC EXPANSION VALVE ....................... 30

6. REMOVAL AND REPLACEMENT OF PRESSURE SWITCH................................................... 31

7. REMOVAL AND REPLACEMENT OF CONTROL WATER VALVE ......................................... 32

8. REMOVAL AND REPLACEMENT OF FLUSH WATER VALVE .............................................. 33

9. REMOVAL AND REPLACEMENT OF FLOAT SWITCH........................................................... 34

10. REMOVAL AND REPLACEMENT OF BIN CONTROL SWITCH ASSEMBLY ......................... 35

11. REMOVAL AND REPLACEMENT OF STORAGE BIN ASSEMBLY ........................................ 36

12. REMOVAL AND REPLACEMENT AGITATOR AND DRIP RING............................................. 37

13. REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY........................................ 38

VI. CLEANING AND MAINTENANCE INSTRUCTIONS................................................................... 41

1. PREPARING THE ICE DISPENSER FOR LONG STORAGE ................................................. 41

2. CLEANING INSTRUCTIONS................................................................................................... 42

[a]CLEANINGPROCEDURE ................................................................................................ 42

[b]SANITIZINGPROCEDURE .............................................................................................. 45

3. MAINTENANCE INSTRUCTIONS ........................................................................................... 46

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I.SPECIFICATIONS

1. DCM-270BAH (Air-cooled)

AC SUPPLY VOLTAGE

AMPERAGE

115/60/1

8.5 A [AT 104°F(40°C)/WT 80°F(27°C)]

MINIMUM CIRCUIT AMPACITY

MAXIMUM FUSE SIZE

APPROXIMATE ICE PRODUCTION

PER 24 HR.

lbs./day ( kg/day )

Reference without *marks

N/A

Ambient

Temp.(°F)

WATER TEMP. (°F)

*282 (128)

248 (113)

219 (99)

192 (87)

271 (123)

238 (108)

*215 (98)

184 (84)

259 (118)

228 (103)

201 (91)

*172 (78)

100

SHAPE OF ICE

Cubelet (compressed flake ice)

ICE QUALITY

Approx. 90%, Ice (90/70°F, Conductivity 200 µs/cm)

8.8 lbs

APPROXIMATE STORAGE CAPACITY

ELECTRIC & WATER CONSUMPTION

ELECTRIC W (kWH/100 lbs.)

POTABLE WATER

90/70°F

686 (7.6)

25.6 (12)

70/50°F

641 (5.5)

32.8 (12)

gal./24HR (gal./100 lbs.)

EXTERIOR DIMENSIONS (WxDxH)

EXTERIOR FINISH

WEIGHT

CONNECTIONS - ELECTRIC

- WATER SUPPLY

16-9/16" x 24-3/16" x 31-7/8" (420 x 615 x 809mm)

Stainless Steel, plastic top

Net 152 lbs. ( 69 kg ), Shipping 170 lbs. ( 77 kg )

Cord Connection

Inlet 1/2" FPT

- DRAIN

Outlet 3/4" MPT

ICE MAKING SYSTEM

HARVESTING SYSTEM

ICE MAKING WATER CONTROL

COOLING WATER CONTROL

BIN CONTROL SYSTEM

COMPRESSOR

Auger type

Direct Driven Auger ( 80 W Gear Motor )

Float Switch

N/A

Mechanical Bin Control ( micro switch )

Hermetic, Model ASE24C3E-IAA-252

Air-cooled, Fin and tube type

Copper Tube on Cylinder

Thermostatic Expansion Valve

CONDENSER

EVAPORATOR

REFRIGERANT CONTROL

REFRIGERANT CHARGE

DESIGN PRESSURE

COMPRESSOR PROTECTION

GEAR MOTOR PROTECTION

REFRIGERANT CIRCUIT PROTECTION

LOW WATER PROTECTION

ACCESSORIES -SUPPLIED

OPERATING CONDITIONS

R-404A

14.8 oz.

(420g)

High 427 PSIG, Low 230 PSIG

Auto-Reset Overload Protector

Manual Reset Circuit Breaker

Auto-reset High Pressure Control Switch

Float Switch and Timer

N/A

VOLTAGE RANGE

104-127 V

45-100° F

45-90° F

AMBIENT TEMP.

WATER SUPPLY TEMP.

WATER SUPPLY PRESSURE

10-113 PSIG

We reserve the right to make changes in specifications and design without prior notice.

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II.GENERALINFORMATION

1. CONSTRUCTION

The Hoshizaki Cubelet Ice Dispenser, model DCM-270BAH includes Water Supply,

Freezer, Condensing, Storage, Dispensing and Control Assemblies.

Fig. 1

Note: *Adjustable Legs

Minimum height - 4"

Maximum height - 5.3"

Do not adjust exceeding the above recommendation.

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2. OPERATION - How it works

Water flows from the potable water source through the Water Supply Line Shut-off Valve,

entersattheWaterInletfittingandintotheWaterReservoir. TheWaterReservoirfunctions

to maintain a constant water level inside the Freezer Assembly. Water from the Water

Reservoir enters at the bottom of the Freezer. Heat is removed by the refrigeration process

and ice forms inside the Freezer.

A stainless steel Auger, located inside the Freezer, is direct-driven by the Gear Motor, and

the rotating Auger carries the ice upward to the end of the Auger, where excess water is

pressed out of the ice, as the ice is extruded and broken into cubelet ice (compressed ice)

and then pushed out into the Storage Bin.

Moving the Power Switch on the bottom left of the Middle Front Panel, to the “ON” position

starts the automatic and continuous icemaking process. When the Ice Storage Bin is filled

with ice, the Bin Control Switch will shut off the icemaking process. As the ice is removed

fromtheStorageBin,theBinControlSwitchresetsautomaticallyandrestartstheicemaking

process.

The Agitator in the Storage Bin keeps the ice from clustering so that the ice can move easily

through the Spout.

Fig. 2

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III. TECHNICAL INFORMATION

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT

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2. PERFORMANCE DATA

DCM-270BAH (Air-cooled)

APPROXIMATE

ICE PRODUCTION

PER 24 HR.

Ambient

Temp. (F)

Water Temp. (F)

(128)

(113)

(99)

(87)

(123)

(108)

(98)

(84)

(123)

(108)

(98)

(84)

(-7)

(118)

(103)

(91)

(78)

(118)

(103)

(91)

(78)

(-7)

(-5)

(-4)

(15.2)

(17.6)

(20.0)

(23.0)

(2.6)

282

248

219

192

641

660

680

694

217

251

285

327

271

238

215

184

647

667

686

697

259

228

201

172

654

673

690

701

100

lbs./DAY ( kg/day)

APPROXIMATE ELECTRIC

CONSUMPTION

watts

(128)

(113)

(99)

(87)

(-7)

(-5)

(-4)

(15.2)

(17.6)

(20.0)

(23.0)

(2.6)

APPROXIMATE WATER

CONSUMPTION PER 24 HR.

gal. / day (l/day)

EVAPORATOR OUTLET TEMP.

°F (°C)

(-5)

(-4)

(15.2)

(17.6)

(20.0)

(23.0)

(2.6)

(2.8)

(3.0)

(3.2)

HEAD PRESSURE

217

251

285

327

217

251

285

327

PSIG (kg/sq.cmG)

SUCTION PRESSURE

PSIG (kg/sq.cmG)

(2.8)

(3.0)

(3.2)

(2.8)

(3.0)

(3.2)

100

TOTAL HEAT OF REJECTION

3532 BTU/h (AT 90°F /WT 70°F)

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.

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3. WIRING DIAGRAM

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4. SEQUENCE OF ELECTRICAL CIRCUIT

A2AAA0269806

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A2AAA0269806

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IV. SERVICE DIAGNOSIS

1. NO ICE PRODUCTION

REMEDY

PROBLEM

POSSIBLE CAUSE

a) Power Supply Cord 1) Broken or loose connection.

[1] The ice

dispenser will

not start.

1) Check for continuity and

replace.

1) Move to “ON” position.

b) Power Switch (on

left bottom of Front

Panel)

1) “OFF” position.

1) Blown out.

c) Fuse

1) Check for short-circuit and

replace.

1) Open.

2) Check and get recom-

mended pressure.

1) Clean.

1A (Control Box)

a) Water Supply Line

1) Shut-off Valve closed.

2) Water supply “OFF”

[2] Water Valve

operates, but

no ice is

b) Water Valve

1) Clogged.

produced.

c) Water Control Relay 1) Bad contacts (Terminal Nos.

4 and 6).

1) Check for continuity and

replace.

2) Coil winding opened.

2) Replace.

3) Loose connections.

3) Tighten.

d) Timer

1) Bad contacts.

1) Check for continuity and

replace.

2) Coil winding opened.

3) Loose connections.

4) Defective.

2) Replace.

3) Tighten.

4) Replace.

a) Compressor

b) Timer

1) Motor winding opened or

grounded.

1) Bad contacts (X2 Relay).

[3] Compressor

will not start.

1) Replace.

1) Check for continuity and

replace.

2) X2 Relay coil winding

opened.

2) Replace.

3) Loose connections.

1) Bad contacts.

3) Tighten.

1) Check for continuity and

replace.

1) Check for continuity and

replace.

1) Replace.

c) Motor Protector

d) Starter

1) Bad contacts.

1) Defective.

e) Starting

Capacitor

a) Gear Motor

b) Timer

1) Motor winding opened.

1) Bad contacts (X1 Relay).

[4] Gear Motor

will not start.

1) Replace.

1) Check for continuity and

replace.

c) Protect Relay

1) Bad contacts.

1) Check for continuity and

replace.

2) Coil winding opened.

3) Loose connections.

1) Bad Contact.

2) Replace.

3) Tighten.

1) Check for continuity and

replace.

1) Replace.

d) Protector

e) Capacitor

1) Defective

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REMEDY

PROBLEM

POSSIBLE CAUSE

a) Fan Motor

b) Timer

[5] Fan Motor

will not start.

1) Motor winding opened.

2) Bearing worn out.

3) Wiring to Fan Motor.

1) Replace.

2) Replace.

3) Check for loose connec-

tion or open, and replace.

4) Check and replace.

1) Check for continuity and

replace.

4) Fan blade bound.

1) Bad contacts (X2 Relay).

2) X2 Relay coil winding

opened.

2) Replace.

3) Loose connections.

1) Water failure or pressure

too low.

3) Tighten.

a) Water supply

[6] No water or

poor flow.

1) Wait until water is sup-

plied, or adjust the

pressure range within

10-113 PSIG.

2) Shut-off Valve closed or

restricted.

2. Open.

b) Water Valve

1) Clogged filter.

1) Clean.

2) Coil winding opened.

1) Contacts fused.

2) Clogged.

2) Replace.

1) Replace.

2) Clean.

c) Float Switch

d) Water Control Relay

1) Bad Contacts (Terminal

Nos. 1 and 5).

1) Check for continuity and

replace.

2) Contacts fused (Terminal

Nos. 3 and 5).

1) Replace.

e) Bin Control Switch

f) Ice Making Switch

1) Bad contacts.

1) Check for continuity and

replace.

1) Move to “ON” position.

2) Check for continuity and

replace.

1) “OFF” position.

2) Bad contacts.

a) Float Switch

[7] Ice dispenser

will not stop

even if out of

water.

1) Contacts fused.

2) Clogged.

1) Contacts fused (Terminal

Nos. 4 and 6).

1) Replace.

2) Clean.

1) Replace.

b) Water Control Relay

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2. LOW ICE PRODUCTION

REMEDY

PROBLEM

POSSIBLE CAUSE

a) Condenser

1) Dirty Air Filter or Condenser.

2) Bad ventilation.

[1] Abnormal

refrigeration

circuit.

1) Clean.

2) Remove anything blocking

vents.

b) Thermostatic Expan- 1) Low-side pressure or tem-

1) Secure bulb to low-side

line or replace.

sion Valve

perature exceeding the

limit.

c) Refrigerant Lines

1) Gas leaks.

1) Check for leaks with a

leak detector. Reweld

leak, replace drier and

charge with refrigerant.

The amount of refrigerant

is marked on Nameplate.

2) Recharge.

2) Overcharged.

d) Compressor Motor

Protector

e) Inside wall of

Evaporator

1) Overload Protector stops

Compressor intermittently.

1) Scale on inside wall of

Freezing Cylinder.

1) Check Condenser and

Fan Motor.

1) Remove Auger, use

Hoshizaki “Scale Away”

or “LIME-A-WAY” solution

to clean periodically.

If water is found to sur-

pass the following levels,

install a conditioner:

Hardness 50 ppm

Silica

1) Clean.

2) Remove anything blocking

vents.

30 ppm

a) Condenser

1) Dirty Air Filter or Condenser.

2) Bad ventilation.

[2] Condensing

temperature

too high.

3) Ambient temperature too

high.

3) Check ventilation and

location, and change as

needed.

4) Less than 6" clearance at

rear, sides and top.

4) Allow proper clearance for

ventilation.

b) Fan Motor

a) Water supply

1) Fan revolving too slowly.

1) Water pressure too low.

1) See chart 1 - [5] - a).

1) See chart 1 - [6] - a).

[3] Poor water

flow.

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3. FAULTY DISPENSER

REMEDY

PROBLEM

POSSIBLE CAUSE

a) Storage Bin

b) Agitator

1) Ice block or bridge

[1] No ice is

dispensed.

1) Remove all ice from

Storage Bin when not

using ice dispenser for a

long time.

1) Deformed due to ice block

or bridge.

1) Replace.

c) Solenoid

1) Coil winding opened.

1) Bad contacts.

1) Replace.

1) Check for continuity and

replace.

1) Check for continuity and

replace.

1) Clean.

d) Ice Switch or Dis-

pensing Switch

e) Ice Dispensing

Relay

a) Water Valve (Dis-

pensing)

b) Water Dispensing

Switch

a) Shutter

1) Bad contacts.

1) Clogged Filter.

1) Bad contacts.

1) Faulty adjustment.

[2] No water is

dispensed.

1) Check for continuity and

replace.

[3] Ice keeps

being dis-

pensed.

1) With Shutter closed, lock

Shutter in place by

securing with two screws

at the lower part of

Solenoid and two screws

under Solenoid.

b) Ice Switch

1) Contacts fused.

1) Replace.

Dispensing Switch

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4. OTHERS

REMEDY

PROBLEM

POSSIBLE CAUSE

a) Bin Control Switch

1) Contacts fused.

2) Out of position.

[1] Ice dispenser

will not stop

even if filled

with ice.

1) Replace.

2) Reinstall.

1) Replace.

b) Water Control Relay 1) Contacts fused.

c) Timer

1) Defective.

a) Water Supply

1) Water pressure too high.

[2] Reservoir

overflows.

1) If pressure is consistently

too high, install a pres-

sure reducing valve.

1) Clean or replace.

1) Check for continuity and

replace.

(Water will

not stop.)

b) Water Valve

c) Float Switch

1) Cannot close.

1) Bad contacts (red and black

leads).

2) Defective.

2) Replace.

d) Water Control Relay 1) Coil winding opened.

2) Bad contacts (Terminal Nos.

1 and 3).

1) Replace.

2) Check for continuity and

replace.

a) Mechanical seal

1) Dirt stuck on seal surface.

[3] A lot of water

drains from

Gear Motor

Drain Pipe.

[4] Abnormal

noise.

1) Clean or replace.

2) Replace.

(normally less than 2) Worn out.

0.017 fl. oz./hour)

a) Fan Motor

1) Bearings worn out.

1) Replace.

2) Replace Fan Blade.

3) Remove the object.

2) Fan Blade deformed.

3) Fan Blade caught on foreign

object.

b) Compressor

c) Refrigerant Lines

1) Bearings worn out, or

cylinder valve broken.

2) Mounting pad out of posi-

tion.

1) Rubbing or touching lines or

other surfaces.

1) Replace.

2) Reinstall.

1) Replace.

d) Gear Motor (Ice

Making)

1) Bearing or Gear wear/

damage.

1) Replace.

e) Evaporator

1) Scale on inside wall of

Freezing Cylinder.

1) Worn out.

2) Foreign matter on Plunger

surface.

1) See chart 2 - [1] - e).

f) Solenoid (Shutter)

1) Replace.

2) Clean.

g) Water Valve

h) Extruding Head

i) Housing

1) Foreign matter on Plunger.

1) Bearing worn out.

1) Clean.

1) Replace.

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V. REMOVAL AND REPLACEMENT OF COMPONENTS

IMPORTANT

Ensure all components, fasteners and thumbscrews are securely in place

after the equipment is serviced.

IMPORTANT

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

system when replacing or servicing parts.

2. Always install a new filter drier every time the sealed refrigeration system is

opened.

3. Do not leave the system open for longer than 5 minutes when

replacing or servicing parts.

1. SERVICE FOR REFRIGERANT LINES

[a] REFRIGERANT RECOVERY

The icemaker unit is provided with two Refrigerant Access Valves–one on the low-side and

one on the high-side line. Using proper refrigerant practices, recover the refrigerant from

these two Access Valves and store it in an approved container. Do not discharge the

refrigerant into the atmosphere.

[b] EVACUATION AND RECHARGE [R-404A]

1) Attach Charging Hoses, a Service Manifold and a Vacuum Pump to the system. Be

sure to connect charging hoses to both High and Low -side Access Valves.

IMPORTANT

The vacuum level and Vacuum Pump may be the same as those for

current refrigerants. However, the rubber hose and gauge manifold to be used

for evacuation and refrigerant charge should be exclusively for POE oils.

2) Turn on the Vacuum Pump. Never allow the oil in the Vacuum Pump to flow

backward.

3) Allow the Vacuum Pump to pull down to a 29.9" Hg vacuum. Evacuating period

depends on pump capacity.

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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 reclaimed refrigerant which meets

ARI Standard No. 700-88 be used.

6) A liquid charge is recommended for charging an R-404A system. Invert the service

cylinder. Open the High-side, Service Manifold Valve.

7) Allow the system to charge with liquid until the pressures balance.

8) If necessary, add any remaining charge to the system through the Low-side. Use a

throttling valve or liquid dispensing device to add the remaining liquid charge

through the Low-side access port with the unit running.

9) Close the two Refrigerant Access Valves, and disconnect the Hoses and Service

Manifold.

10) Cap the Access Valves to prevent a possible leak.

2. BRAZING

DANGER

1. Refrigerant R-404A itself is not flammable at atmospheric pressure and

temperatures up to 176° F.

2. Refrigerant R-404A itself is not explosive or poisonous. However, when

exposed to high temperatures (open flames) R-404A can be decomposed

to form hydrofluoric acid and carbonyl fluoride both of which are hazardous.

3. Always recover the refrigerant and store it in an approved container. Do not

discharge the refrigerant into the atmosphere.

4. Do not use silver alloy or copper alloy containing Arsenic.

5. Do not use R-404A as a mixture with pressurized air for leak testing. Refrig-

erant leaks can be detected by charging the unit with a little refrigerant,

raising the pressure with nitrogen and using an electronic leak detector.

Note: All brazing connections inside the bin are clear-paint coated.

Sandpaper the brazing connections before unbrazing the components.

Use a good abrasive cloth to remove coating.

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3. REMOVAL AND REPLACEMENT OF COMPRESSOR

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is

opened. Do not replace the Drier until after all other repair or replacement

has been made.

Note: When replacing a Compressor with a defective winding, be sure to

install the new Start Capacitor and Start Relay supplied with the re

placement Compressor. Due to the ability of the POE oil in the com-

pressor to absorb moisture quickly, the Compressor must not be

opened more than 15 minutes for replacement or service. Do not mix

lubricants of different compressors even if both are charged with

R-404A, except when they use the same lubricant.

1) Turn off the power supply and unplug the dispenser.

2) Remove the panels.

3) Remove the Terminal Cover on the Compressor, and disconnect the Compressor

Wiring.

4) Recover the refrigerant and store it in an approved container.

5) Remove the Discharge and Suction Pipes using brazing equipment.

WARNING

When repairing a refrigerant system, be careful not to let the burner flame

contact the lead wires or insulation.

6) Remove the Hold-down Bolts, Washers and Rubber Grommets.

7) Slide and remove the Compressor. Unpack the new Compressor package. Install the

new Compressor.

8) Attach the Rubber Grommets of the prior Compressor.

9) Sandpaper the Suction, Discharge and Process Pipes.

10) Place the Compressor in position, and secure it using the Bolts and Washers.

11) Remove plugs from the Suction, Discharge and Process Pipes.

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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 system, and charge it with refrigerant. See the Nameplate for the

required refrigerant charge.

17) Replace the panels in their correct positions.

18) Plug in the dispenser and turn on the power supply.

4. REMOVAL AND REPLACEMENT OF DRIER

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is

opened. Do not replace the Drier until after all other repair or replacement

has been made.

1) Turn off the power supply and unplug the icemaker.

2) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the Drier using brazing equipment.

5) Install the new Drier, in the direction of the refrigerant flow. Use nitrogen gas at the pressure

of 3-4 PSIG when brazing the tubings.

6) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

7) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required

refrigerant charge.

8) Replace the panels in their correct positions.

9) Plug in the dispenser, and turn on the power supply.

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5. REMOVALAND REPLACEMENT OF THERMOSTATIC EXPANSION VALVE

IMPORTANT

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 made.

1) Turn off the power supply, and unplug the dispenser.

2) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the insulation and the Expansion Valve Bulb on the suction line.

5) Remove the Expansion Valve Cover, and disconnect the Expansion Valve using

brazing equipment.

6) Braze the new Expansion Valve, with nitrogen gas flowing at the pressure of

3-4 PSIG.

WARNING

1. Do not heat the wall. Place a steel barrier for protection.

2. Always protect the valve body by using a damp cloth to prevent the valve

from overheating. Do not braze with the valve body exceeding 250°F.

7) Install the new Drier.

8) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

9) Evacuate the system, and charge it with refrigerant. See the Nameplate for the

required refrigerant charge.

10) Place the Expansion Valve in position.

11) Place the new set of Expansion Valve Covers in position.

12) Attach the Expansion Valve Bulb to the low-side line, and secure it with Bulb Holder and

Clamps.

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13) Cover the Expansion Valve Bulb tightly with the insulation.

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

IMPORTANT

Always install a new Drier every time the sealed refrigeration system is

opened. Do not replace the Drier until after all other repair or replacement

has been made.

1) Turn off the power supply and unplug the dispenser.

2) Remove the panels.

3) Recover the refrigerant and store it in an approved container.

4) Remove the Control Box Cover and disconnect the terminals.

5) Remove the Pressure Switch using brazing equipment.

6) Braze the new Pressure Switch with nitrogen gas flowing at the pressure of 3-4 PSIG.

7) Install the new Drier.

8) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.

9) Evacuate the system, and charge it with refrigerant. See the Nameplate for the

required refrigerant charge.

10) Replace the terminals and the Control Box Cover in their correct positions.

11) Replace the panels in their correct positions.

12) Plug in the dispenser and turn on the power supply.

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7. REMOVAL AND REPLACEMENT OF CONTROL WATER VALVE

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 Nut.

6) Remove the Water Supply Hose from the Control Water Valve.

7) Install the new Control Water Valve.

8) Assemble the removed parts in the reverse order of the above procedure.

9) Open the Water Supply Line Shut-off Valve.

10) Check for water leaks.

11) Replace the panels in their correct position.

12) Plug in the icemaker.

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8. REMOVAL AND REPLACEMENT OF FLUSH WATER VALVE

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

Drain Pan.

5) Disconnect the Flush Water Valve from the tube connected to the plastic tee leading to

the drain hose.

6) Disconnect the Terminals from the Flush Water Valve.

7) Remove the Flush Water Valve from the Frame or Bracket.

8) Connect the new Flush Water Valve back onto the Frame or Bracket.

9) Connect the tube from the plastic tee to the new Flush Water Valve.

10) Connect the Hose to the Flush Water Valve and secure it with the Clamp.

11) Pour water into the Reservoir, and check for water leaks on the Flush Water Valve.

12) Open the Water Supply Line Shut-off Valve.

13) Turn on the power supply.

14) Move the Flush Switch to the “ICE” position.

15) Check for water leaks.

16) Move the Flush Switch to the “FLUSH” position, and make sure water is flushing.

17) Move the Flush Switch to the “ICE” position.

18) Replace the panels in their correct position.

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9. REMOVAL AND REPLACEMENT OF FLOAT SWITCH

WARNING

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) Flush water out of the system.

5) Cut the Float Switch leads at the wire connectors.

6) Turn and unfasten the flanged top, and remove the Float Switch.

7) Install the new Float Switch.

8) Assemble the removed parts in the reverse order of which they were removed.

9) Open the Water Supply Line Shut-off Valve.

10) Plug in the dispenser, turn on the power supply and check that the Float Switch works

normally.

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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

switch.

8) Plug in the dispenser, turn on the power supply and check that the Bin Control Switch

works normally.

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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 Plate and Shutter Assembly.

7) Remove the three Socket Head Cap Screws and lift off the Storage Bin Assembly.

8) Install the new Storage Bin Assembly.

9) Assemble the removed parts in the reverse order of which they were removed.

10) Plug in the dispenser and turn on the power supply.

11) Move the Shutter to check for proper operation.

12) Move the Ice Making Switch to the “ON” position.

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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 and lift off.

7) Rotate the Drip Ring about 30 degrees clockwise and lift off.

8) Install the new Drip Ring and Agitator.

9) Assemble the removed parts in the reverse order of which they were removed.

10) Plug in the dispenser and turn on the power supply.

11) Move the Ice Making Switch to the “ON” position.

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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 “11. REMOVAL AND REPLACEMENT OF

STORAGE BIN ASSEMBLY.”)

EXTRUDINGHEAD

7) Lift off the Extruding Head.

8) Replace the Bearing inside the Extruding Head, if it is worn or scratched.

Note: Replacing the Bearing requires a fitting tool.

If one is not available, replace the whole

Extruding Head.

AUGER

9) Lift up and turn the Auger until it comes off. If the area in contact with the Bearings

worn out or the Blade is scratched, replace the Auger.

EVAPORATOR

Note: Skip the following steps 10) through 17) when the

Evaporator does not need replacement.

10) Recover the refrigerant and store it in an approved container.

WARNING

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.

11) Remove the Expansion Valve Cover.

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12) Remove the Insulation and the two Clamps on the Expansion Valve Bulb.

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 the 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 it with refrigerant. See the Nameplate for the required

refrigerant charge.

18) Remove the four Socket Head Cap Screws at the bottom of the Evaporator.

19) Disconnect the Hose from the Evaporator.

20) Lift off the Evaporator.

HOUSINGANDMECHANICALSEAL

21) Remove the four Hexagon Bolts securing the Housing to the Gear Motor.

22) Remove the Mechanical Seal fixed on the Housing.

Note: The Mechanical Seal consists of two parts. One moves along

with the Auger, and the other is fixed on the Housing. If the

contact surfaces of these two parts is worn or scratched, the

Mechanical Seal may cause water leaks and should be

replaced.

23) Replace the Bearing inside the Housing using a fitting tool, if the Bearing is worn or

scratched.

Note: Replacing the Bearing requires a fitting too. If one is not

available, replace the whole Housing. Be sure to install

the O-ring

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GEAR MOTOR

24) Cut the Gear Motor leads at the wire connector.

25) Remove the three Hexagon Bolts securing the Gear Motor on the chassis.

26) Remove the Gear Motor.

27) Install the new Gear Motor.

28) Assemble the removed parts in the reverse order of which they were removed

WARNING

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.

WARNING

After assembling the Extruding Head, be sure to check that the Auger does

not come into contact with the inner surface of the Evaporator and that there

is not any abnormal noise from the Bearing.

30) Turn on the power supply.

31) Move the Ice Making Switch to the “ON” position.

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VI. CLEANING AND MAINTENANCE INSTRUCTIONS

IMPORTANT

Ensure all components, fasteners and thumbscrews are securely in place after

any maintenance or cleaning is done to the equipment.

1. PREPARING THE ICE DISPENSER FOR LONG STORAGE

IMPORTANT

When shutting off the ice dispenser for an extended time, drain out all water

from the water line and remove the ice from the Storage Bin. The Storage Bin

should be cleaned and dried. Drain the ice dispenser to prevent damage to

the water supply line at sub-freezing temperatures, using air or carbon diox-

ide. Shut off the ice dispenser until the proper ambient temperature is

resumed.

1. Close the Water Supply Line Shut-off Valve.

2. Move the Ice Making Switch, located on the Control Box, to the “FLUSH” position.

3. Press the Push Button for ice dispensing, and remove all ice from the Storage Bin.

4. Wait until all water is drained out through Drain Pan, and move Power Switch to the “OFF”

position.

5. Unplug the Ice Dispenser.

IMPORTANT

Before operating the dispenser next time, open the Water Supply Line Shut-off

Valve.

Note: When shutting off the ice dispenser

at sub-freezing temperatures, run

the ice dispenser with the Water

Supply Line Shut-off Valve closed,

and blow out the water inlet line by

using air pressure.

Fig. 3

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2. CLEANING INSTRUCTIONS

IMPORTANT

Ensure all components, fasteners and thumbscrews are securely in place

after any maintenance or cleaning is done to the equipment.

WARNING

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 cleaning and

sanitizing solutions. This will prevent irritation in case the solution contacts

the skin.

[a] CLEANING PROCEDURE

1. Close the Water Supply Line Shut-off Valve.

2. Dilute approximately 6 fl. oz. of recommended cleaner Hoshizaki “Scale Away” or

“LIME-A-WAY” (manufactured by Economics Laboratory, Inc.) with 1 gal. of water.

3. Move the Ice Making Switch, located on the Control Box, to the “FLUSH” position.

4. Press the “ICE” Push button, and remove all ice form the Storage Bin.

5. After water has drained out through the Drain Pan, move the Power Switch to the

“OFF” position.

6. Remove Spouts (A) and (B) by removing the Thumbscrew, sliding the Spouts back-

ward and then pulling them down. (See Fig. 4.)

7. Pull out Spout (A) from Spout (B).

8. Remove the Top Panel and Storage Bin Cover. (See Fig. 5.)

9. Remove the Agitator and Drip Ring. Wipe, using a clean cloth containing the

cleaning solution.

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Fig. 4

Fig. 5

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10. Pour the cleaning solution carefully into the Reservoir through the opening in the center

of the Storage bin up to an overflow level. (Solution that has overflowed can be seen

in the Drain Pan.)

11. While waiting for 10 minutes to start icemaking process, wipe the Bin Liner and the

Drip Plate using a clean cloth containing the cleaning solution.

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 to

begin (60 seconds).

15. Pour clean, warm water carefully onto the Bin Liner, Agitator, Drip Ring and into the

Reservoir through the opening in the center of the Storage Bin to melt the ice and

rinse out the cleaning solution.

16. Move the Power Switch to the “OFF” position.

17. Wipe the Storage Bin Cover and Spouts (A) and (B) using a clean cloth containing the

cleaning solution.

18. Rinse the wiped parts with water. Be careful not to wet the Bin Control Switch on the

Storage Bin Cover.

CAUTION

Do not use ice produced with cleaning and sanitizing solutions. Be sure none

remains in the Storage Bin.

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[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 Making Switch to the

“ON” position, and start automatic icemaking process. Run the ice dispenser until it

stops automatically.

4. Move the Ice Making Switch to the “FLUSH” position.

5. Wipe the Bin Liner and the Drip Plate using a clean cloth containing the sanitizing solu-

tion.

6. Pour clean, warm water carefully onto the Bin Liner and into the Reservoir through the

opening in the center of the Storage Bin to melt the ice and rinse out the sanitizing

solution. Be careful not to wet the Bin Control Switch on the Storage Bin Cover.

7. Remove the Bin Control Switch from the Storage Bin Cover, and immerse the Storage

Bin Cover, Agitator, Drip Ring and Spouts (A) and (B) in the sanitizing solution.

8. Rinse the parts sanitized above, using water.

9. Place the parts rinsed above back in position. Reattach the Bin Control Switch to the

Storage Bin Cover.

10. After water has drained out through the Drain Pan, open the water supply line shut-off

valve and move the Ice Making Switch to the “ON” position. Run the ice dispenser for

30 minutes.

11. Move the Ice Making Switch to the “FLUSH” position, and let all water drain out through

the Drain Pan.

12. Press the “ICE” Push Button, and remove all ice from the Storage Bin.

13. Place the Top Panel in position.

14. Move the Ice Making Switch to the “ON” position, and start the automatic and

continuous icemaking process.

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2. MAINTENANCE INSTRUCTIONS

IMPORTANT

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 dirt build up.

2) Air Filter - See Fig. 6

A plastic mesh air filter removes dirt or dust from the air, and keeps the Condenser from

getting clogged. As the filter gets clogged, the ice dispenser’s performance will be

reduced. Check the filter at least twice a month. When clogged, use warm water and

a neutral cleaner to wash the filter.

3) Condenser

Check the Condenser once a year, and clean if required by using a brush or vacuum

cleaner. More frequent cleaning may be required depending on the location of the ice

dispenser.

Fig. 6

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