Hoshizaki Refrigerator 73168 User Manual

Hoshizaki America, Inc.  
Hoshizaki  
Commercial Kitchen Equipment  
Model  
Refrigerated Prep Table with Raised Rail  
SERVICE MANUAL  
“A Superior Degree  
of Reliability”  
Number: 73168  
Issued: 8-12-2009  
Revised: 5-11-2011  
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IMPORTANT  
This manual should be read carefully before the unit is serviced or  
maintenance operations are performed. Only qualified service technicians  
should install, service, and maintain the unit. Read the warnings contained  
in this booklet carefully as they give important information regarding safety.  
Please retain this booklet for any further reference that may be necessary.  
CONTENTS  
3
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Important Safety Information  
Throughout this manual, notices appear to bring your attention to situations which could  
result in death, serious injury, or damage to the unit.  
WARNING  
Indicates a hazardous situation which could result in death or  
serious injury.  
CAUTION  
IMPORTANT  
Indicates a situation which could result in damage to the unit.  
Indicates important information about the use and care of the  
unit.  
WARNING  
This unit should be destined only to the use for which it has been expressly  
conceived. Any other use should be considered improper and therefore  
dangerous. The manufacturer cannot be held responsible for eventual damage  
caused by improper, incorrect, and unreasonable use.  
To reduce the risk of death, electric shock, serious injury, or fire, follow  
basic precautions including the following:  
• This unit requires an independent power supply. See the nameplate for  
proper voltage and breaker/fuse size. Failure to use a proper breaker or fuse  
can result in a tripped breaker, blown fuse, or damage to existing wiring. This  
could lead to heat generation or fire.  
THIS APPLIANCE MUST BE GROUNDED: This unit is equipped with a  
3-prong grounding plug to reduce the risk of potential shock hazards. It must  
be plugged into a properly grounded, independent 3-prong wall outlet. If the  
outlet is a 2-prong outlet, it is your personal responsibility to have a qualified  
electrician replace it with a properly grounded, independent 3-prong wall  
outlet. Do not remove the ground prong from the power cord and do not use  
an adapter plug.  
• Do not use an extension cord.  
• Make sure the power switch is in the "OFF" position before plugging in or  
unplugging the unit to reduce the risk of electric shock.  
• Do not use a unit with a damaged power cord. The power cord should not be  
altered, jerked, bundled, weighed down, pinched, or tangled. Such actions  
could result in electric shock or fire. To unplug the unit, be sure to pull the  
plug, not the cord, and do not jerk the cord.  
To reduce the risk of electric shock, do not touch the plug or power switch  
with damp hands.  
• This unit should be disassembled or repaired only by qualified service  
personnel to reduce the risk of electric shock, injury, or fire.  
• Do not make any alterations to the unit. Alterations could result in electric  
shock, injury, re, or damage to the unit.  
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I. Specifications  
A. Nameplate Ratings  
Design Pressure (PSIG)  
Refrigerant  
404A  
HI  
LO  
Model  
AC Supply Voltage  
Amperes  
HPR46A(-D)  
HPR72A  
HPR72A-D  
HPR100A(-D)  
7. 6  
See Unit Nameplate  
13.6  
28.5 oz.  
115/60/1  
450  
250  
36.1 oz.  
TBD  
TBD  
B. Dimensions  
Rail  
Exterior Worktop Exterior Exterior  
Interior  
Volume QTY of 1/6  
Capacity  
Height  
(HE)  
Height  
(HW)  
Width  
(W)  
Depth  
(D)  
Interior  
Height  
Interior  
Width  
Interior  
Depth  
Model  
Cu. Ft.  
Sized Pans mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)  
HPR46A(-D)  
(1 Section)  
8.5  
12  
18  
26  
1168.4  
(46)  
604.1  
(23.78)  
HPR72A(-D)  
(2 Section)  
18.8  
29.1  
1828.8  
(72)  
1309.1  
(51.54)  
1040  
(40.95)  
816  
(32.13)  
858.5  
(33.79)  
640.5  
(25.22)  
641.8  
(25.27)  
HPR100A(-D)  
(3 Section)  
2533.8  
(99.76)  
2014.1  
(79.30)  
Door  
Door  
Opening  
Height  
(DH)  
Opening  
Width  
(DW)  
Door  
Swing  
(DS)  
Drawer  
Extension  
(DE)  
Drawer  
Gap  
(DG)  
Door  
Open  
Rail Cover Caster  
Open Height  
Model  
mm (in.)  
mm (in.)  
mm (in.)  
mm (in.)  
mm (in.) Position Positions mm (in.)  
HPR46A(-D)  
(1 Section)  
45°  
and  
65°  
HPR72A(-D)  
(2 Section)  
616.2  
(24.26)  
570.3  
(22.45)  
608.3  
(23.95)  
649.1  
(25.56)  
19  
(0.75)  
101.6  
(4)  
105°  
HPR100A(-D)  
(3 Section)  
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II. General Information  
A. Construction  
This Hoshizaki unit features a cartridge-type refrigeration system that can be removed  
(excluding the rail evaporator).  
Rail Cover  
Rail Fan Motors and  
Fan Shrouds  
Compressor  
Side Panel  
Front Panel  
Receiver Tank  
Air Filter  
Drier  
Control Box  
Condenser Fan Motor  
Wire Cover  
Condenser  
Cabinet Evaporator  
Assembly  
Cabinet Evaporator  
Fan Motors  
Cabinet Defrost Thermistor  
Refrigeration  
Cartridge  
Cabinet Thermistor  
Defrost Thermostat  
Cabinet Air Duct  
Cabinet Interior Side  
Panel  
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B. Sequence of Operation  
The steps in the sequence are as outlined below.  
1. Startup  
When the power switch is in the "ON" position, the cabinet temperature is displayed  
and cabinet cooling begins. When the power switch is in the "ON" position and the rail  
cooling switch is moved to the "NORMAL" or "LOW" position, the rail temperature is  
displayed and rail cooling begins. The "NORMAL" rail switch position is designed for use  
when the rail cover is open. The "LOW" rail switch position is designed for use when the  
rail cover is closed. For further details, see "II.D.4.a) Switch Settings."  
a) Power Switch "ON," Rail Cooling Switch "OFF"  
Cabinet temperature at or above setpoint: CabFM, CLLV, and PH energize. The  
2 minute Comp delay timer and 6 hour DT start.  
b) Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"  
Cabinet temperature and rail temperature at or above setpoint: CabFM, CLLV, PH,  
RailFM, and RLLV energize. The 2 minute Comp delay timer and 6 hour DT start.  
2. Cool Down  
a) Power Switch "ON," Rail Cooling Switch "OFF"  
CabFM, CLLV, and PH continue. The 2 minute Comp delay timer expires and Comp  
and ConFM energize.  
b) Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"  
CabFM, CLLV, PH, RailFM, and RLLV continue. The 2 minute Comp delay timer  
expires and Comp and ConFM energize.  
3. Cool Down Achieved  
To prevent Comp hard starts, CLLV (rail cooling switch "OFF") or RLLV (rail cooling  
switch "NORMAL" or "LOW") remains energized when Comp is off.  
a) Power Switch "ON," Rail Cooling Switch "OFF"  
CTh reaches 3.6°F (2°C) below setpoint. CabFM and PH continue, Comp and ConFM  
de-energize. CLLV de-energizes for 2 seconds (CLLV then remains energized during  
Comp off time).  
b) Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"  
CTh, RTh, or both have reached 3.6°F (2°C) below setpoint.  
(1) Cabinet still cooling, RTh reaches 3.6°F (2°C) below setpoint  
CabFM, Comp, CondFM, CLLV, and PH continue. RailFM continues when rail  
cooling switch is in the "NORMAL" position and per F9 setting when in the "LOW"  
position. For details, see "II.D.4.a) Switch Settings." RLLV de‑energizes.  
(2) CTh reaches 3.6°F (2°C) below setpoint, rail still cooling  
CabFM, Comp, CondFM, PH, RailFM, and RLLV continue. CLLV de-energizes.  
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(3) Both CTh and RTh reach 3.6°F (2°C) below setpoint  
CabFM and PH continue. RailFM continues when rail cooling switch is in the  
"NORMAL" position and per F9 setting when in the "LOW" position. For details,  
see "II.D.4.a) Switch Settings." Comp, ConFM, and CLLV de‑energize. RLLV  
de-energizes for 2 seconds. RLLV energizes, then remains energized during  
Comp off time.  
4. Cool Down Restart  
a) Power Switch "ON," Rail Cooling Switch "OFF"  
CTh warms to setpoint, the CabFM, CLLV, and PH continue. 2 minute Comp delay  
timer starts. After the 2 minute delay timer expires, Comp and ConFM energize.  
Cycle continues until power is turned off, the 6 hour DT expires and CB initiates  
a cabinet defrost, or the "MANUAL DEFROST" button is pressed for 5 seconds  
(evaporator temperature must be below 49°F (9.4°C)).  
b) Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"  
CTh, RTh, or both have warmed to setpoint.  
(1) CTh at or above setpoint, RTh warms to setpoint  
CabFM, Comp, ConFM, CLLV, PH, continue. RailFM continues when rail switch is  
in the "NORMAL" position and resumes continuous operation when in the "LOW"  
position. RLLV energizes.  
(2) CTh warms to setpoint, RTh at or above setpoint  
CabFM, Comp, ConFM, PH, RailFM, and RLLV continue. CLLV energizes.  
(3) CTh or RTh warms to setpoint  
CabFM, PH, RailFM (RailFM continues when rail switch is in the "NORMAL"  
position and resumes continuous operation when in the "LOW" position), and  
RLLV continue. The 2 minute Comp delay timer starts. If CTh has warmed to  
setpoint and RTh has not, CLLV energizes and RLLV de-energizes. If RTh  
has warmed to setpoint and CTh has not, RLLV continues and CLLV remains  
de-energized. After the 2 minute Comp delay timer expires, Comp and ConFM  
energize.  
5. Cabinet Defrost  
The first cabinet defrost occurs 6 hours after the unit is turned on. Cabinet defrost is  
initiated when the 6 hour DT expires or the "MANUAL DEFROST" button is pressed  
for 5 seconds. Cabinet defrost termination occurs when the evaporator temperature  
reaches 49°F (9.4°C). Note that the defrost is a heated defrost, and therefore will have a  
tendency to raise the cabinet temperature. Cabinet temperature is not displayed during  
defrost; "dF" is displayed in its place. After defrost, there is a 5 minute delay before the  
compressor will start.  
Note: To prevent Comp hard starts, CLLV (rail cooling switch "OFF") or RLLV (rail  
cooling switch "NORMAL" or "LOW") remains energized when Comp is off.  
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a) Cabinet Defrost: Power Switch "ON," Rail Cooling Switch "OFF"  
CLLV continues, CabFM, Comp, ConFM, and PH de-energize. DH energizes and  
warms DTh to 49°F (9.4°C) (or the 100-minute defrost termination timer expires  
or DTst warms to 120°F 5°F (49°C 3°C)). When DTh reaches 49°F (9.4°C),  
DH de-energizes, CLLV continues and a 5 minute Comp delay timer starts. When the  
5-minute Comp delay timer expires, CabFM and PH energize for 10 seconds. Comp  
and ConFM then energize and a 5-minute CabFM and PH delay timer starts. After the  
5-minute CabFM and PH delay timer expires, CabFM and PH energize.  
b) Cabinet Defrost: Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"  
(1) Cabinet cool down achieved, rail still cooling  
Comp, CondFM, RailFM, and RLLV continue. CabFM and PH de-energize, and  
CLLV remains de-energized. DH energizes and warms DTh to 49°F (9.4°C) (or  
the 100-minute defrost termination timer expires or the DTst warms to 120°F 5°F  
(49°C 3°C)). When DTh reaches 49°F (9.4°C), DH de-energizes, Comp, ConFM,  
RailFM, and RLLV continue. CabFM and PH energize for 10 seconds. CLLV then  
energizes and a 5-minute CabFM and PH delay timer starts. After the 5-minute  
CabFM and PH delay timer expires, CabFM and PH energize.  
(2) Cabinet still cooling, rail cool down achieved  
RailFM continues (RailFM continues when rail switch is in the "NORMAL"  
position and per F9 setting when in the "LOW" position), RLLV and DH energize,  
CabFM, Comp, ConFM, and PH de-energize. CLLV de-energizes for 2 seconds,  
then energizes again. DH warms DTh to 49°F (9.4°C) (or the 100-minute  
defrost termination timer expires or the DTst warms to 120°F 5°F (49°C 3°C)).  
When DTh reaches 49°F (9.4°C), DH de-energizes, RailFM continues, RLLV  
de-energizes, CLLV energizes, and a 5-minute Comp delay timer starts. When the  
5-minute Comp delay timer expires, CLLV and RailFM continue. CabFM and PH  
energize for 10 seconds. Comp and ConFM then energize and a 5-minute CabFM  
and PH delay timer starts. After the 5-minute CabFM and PH delay timer expires,  
CabFM and PH energize.  
6. Rail Defrost  
For rail defrost (manual defrost), remove product from the rail area and store in a  
properly refrigerated area, then move the rail cooling switch to the "OFF" position.  
Legend: CabFM–cabinet fan motor; CB–control board; Comp–compressor;  
ConFM–condenser fan motor; CLLV–cabinet liquid line valve; CTh–cabinet  
thermistor; DH–defrost heater; DT–defrost timer; DTh–defrost thermistor;  
DTst–defrost thermostat; PH–perimeter heater; RailFM–rail fan motor; RLLV–rail  
liquid line valve; RTh–rail thermistor  
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C. Sequence of Operation Charts  
1. Cabinet Cooling  
s e t p o i n t  
o
m s a r t  
C T h w  
12  
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2. Cabinet and Rail Cooling  
s e t p o i n t  
o
m s a r t w  
T h  
C T h o r R  
13  
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2. Cabinet and Rail Cooling (continued)  
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D. Control Board  
• A Hoshizaki exclusive solid‑state control board is employed in all Hoshizaki  
HPR46A(-D), HPR72A(-D), and HPR100A(-D) units.  
• All models are pretested and factory set.  
CAUTION  
1. The control board is fragile; handle very carefully.  
2. The control board contains integrated circuits, which are susceptible to  
failure due to static discharge. It is especially important to touch the metal  
part of the unit when handling or replacing the control board.  
3. Do not touch the electronic devices on the control board or the back of the  
control board.  
4. Do not attempt to repair the control board.  
5. Do not short out power supply to test for voltage.  
6. Keep the thermistor leads and pressure switch leads at least 1.5" (38 mm)  
away from high voltage leads (100Vac or more) to protect against electrical  
noise.  
1. Control Board Location  
The control panel is located behind the front panel. Follow the instructions and warnings  
for safe and efficient operation of the unit.  
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2. Control Board Layout  
"UP" Button  
"DOWN" Button  
Display/Change  
Cabinet Setpoint  
Display/Change  
Rail Setpoint  
Cabinet Temperature,  
Alarm Display, and  
Service Menu  
Rail Temperature,  
Alarm Display, and  
Service Menu  
Energy Saving Mode LED  
(Not used this model)  
"SERVICE USE ONLY" Button  
LED on for  
Negative Values  
"MANUAL DEFROST" button  
Front  
Board Part Number  
K311 Connector  
# 1, 2 Comp Control  
Relay (Brown)  
# 3, 4 Cabinet Evaporator  
Fan Relay (Red)  
K341 Connector  
# 1, 2 Rail Fan Relay (Orange)  
# 5, 6 Defrost Heater  
Relay (Orange)  
Chip Revision  
Fuse 3A 125V  
K101 Connector  
# 1, 3 Transformer 10V  
Control Voltage (Dark Blue)  
K151 Connector  
# 1, 2 Condenser Thermistor  
(Gray) (Clogged Filter  
Thermistor)  
# 3, 4 Defrost Thermistor (Orange)  
(Cabinet) (DTh)  
# 5, 6 Cabinet Thermistor (Black) (CTh)  
# 7, 8 Service Jumper (White)  
K201 Connector  
# 1, 2 Rail Switch (Yellow)  
# 3, 4 Defrost Thermistor  
(Orange. Not used, but must be in  
place)  
# 5, 6 Rail Thermistor (Black) (RTh)  
# 7, 8 Rail Switch (Pink)  
K361 Connector  
# 1, 3 Rail Liquid Line  
Solenoid Valve (RLLV)  
# 1, 5 Cabinet Liquid Line  
Solenoid Valve (CLLV)  
Rear  
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3. Features  
a) LED Display and Service Lock-Out  
This control board uses twin LED displays to show system details and diagnostic  
information. For control board voltage protection, a 3A 125V fuse is incorporated  
into the control board circuitry. A service jumper is also provided to protect against  
unwanted changes to the unit's settings. This service lock-out jumper is located on the  
K151 connector terminals 7 and 8. See "II.D.4. Controls and Adjustments."  
b) Compressor Short Cycle Protection  
The start circuit of the compressor is timed such that at power-up and during any  
compressor off time, there will be at least a 2 minute delay before the compressor will  
start. This protects the compressor against short cycling and potential compressor  
damage or failure. To bypass the 2 minute compressor delay timer (for unit  
diagnostics), press and hold the rail "SET" button and move the power switch to the  
"ON" position.  
c) Alarm Signal  
Alarm signals (E1 to E9, EA and ED) are designed to protect the unit and food  
product. These alarms give information or warnings in the event the unit is operating  
out of acceptable parameters. See "III.A. Alarm Signals."  
d) Service Menu  
A service menu (F0 to F9) allows for viewing and setting of system operating details  
and parameters. See "II.D.5. Service Menu."  
e) Automatic and Manual Defrost Capabilities  
This unit features automatic and manual cabinet defrost capabilities. See "II.D.4.d)  
Cabinet Defrost."  
17  
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4. Controls and Adjustments  
The cabinet and rail temperatures are updated every 30 seconds. The control board is  
supplied with a service jumper on the K151 connector. Only the temperature setpoint  
and the temperature scale ("F5") may be adjusted with this connector in place. To view  
or adjust other selections, see "II.D.5. Service Menu."  
a) Switch Settings  
Power Switch "OFF": Unit off (both cabinet and rail).  
Power Switch "ON": Cabinet temperature is displayed and cabinet cooling begins.  
Cabinet fans and perimeter heaters are on and run continuously (except during defrost).  
Rail Cooling Switch "OFF": Rail cooling off, cabinet cooling continues.  
Rail Cooling Switch "NORMAL: Designed for use when the rail cover is open. Rail  
temperature display on and rail cooling begins. The rail fans operate continuously.  
Rail Cooling Switch "LOW": Designed for use when the rail cover is closed. Rail  
temperature display is on and rail cooling begins. The rail fans operate intermittently  
when "F9" is at the factory default setting. For access and adjustments to the "F9"  
setting, see "II.D.5. Service Menu."  
Note: A Hoshizaki OEM rail cooling switch must be used if replacing the rail cooling  
switch. For details see "IV.M. Rail Cooling Switch."  
b) Temperature Display  
The temperature display can be changed between Fahrenheit and Celsius. To change  
the temperature display, press and hold the cabinet "SET" button and the "SERVICE  
USE ONLY" button for 5 seconds. "F0" appears in the display screen. Press the up  
arrow button until "F5" appears in the display screen. "F5" is the only service menu  
selection accessible with the service jumper in place.  
Press the cabinet "SET" button to view the temperature display setting. Press the up or  
down arrow button to switch between F° and C°. Press the cabinet "SET" button to save  
the new setting. Press the cabinet "SET" button and the "SERVICE USE ONLY" button  
for 5 seconds to return to normal temperature display.  
"SET" buttons used to view current temperature settings.  
Cabinet "SET" button used with "SERVICE USE ONLY"  
button to enter and exit the service menu.  
"UP" and "DOWN" arrow buttons  
used to change temperature  
settings, scroll through the service  
menu, and to change menu settings.  
"SERVICE USE ONLY"  
button used with cabinet  
"SET" button to enter and  
exit the service menu.  
"MANUAL DEFROST"  
button used to initiate  
a manual defrost.  
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c) Temperature Setpoint  
The temperature setpoint is the temperature setting at which the compressor turns on.  
The factory default temperature setpoints are 37° (3°C) for the cabinet and 33°F (1°C)  
for the rail (see the chart below).  
The temperature differential for the compressor to turn off is 3.6°F (2°C) below the  
temperature setpoint. The temperatures are updated every 30 seconds. If necessary,  
adjust the temperature setpoint as outlined below.  
Note: The cabinet and rail temperature setpoints must be changed individually.  
1) Press the appropriate "SET" button to display the current temperature setpoint.  
2) Press and hold the appropriate "SET" button while pressing the up or down arrow  
button. See the chart below for temperature setpoint ranges.  
3) Release the "SET" button. As long as the unit is not turned off, the new setpoint will be  
saved automatically after 10 seconds.  
Section Temperature Setpoint Range  
Default  
21 to 53°F  
(-6 to +12°C)  
37°F  
(3°C)  
Cabinet  
-13 to +53°F  
(-25 to +12°C)  
33°F  
(1°C)  
Rail  
d) Cabinet Defrost  
The automatic cabinet defrost is factory set for once every 6 hours. See "II.D.5. Service  
Menu." The cabinet defrost thermistor will signal the control board to start a defrost once  
the 6 hour defrost timer has expired and the cabinet evaporator temperature is below  
49°F (9.4°C). Defrost is heated, and therefore will have a tendency to raise the cabinet  
temperature.  
For a manual cabinet defrost press the "MANUAL DEFROST" button on the control  
board for 5 seconds to initiate a defrost. This will restart the 6-hour defrost timer.  
Cabinet temperature is not displayed during defrost; "dF" is displayed in its place. The  
control board will terminate the cabinet defrost and begin defrost recovery when a signal  
from the cabinet defrost thermistor is greater than 49°F (9.4°C). After defrost, there is a  
5-minute delay before the compressor will start.  
This unit has an additional defrost thermistor located behind the wire cover that connects  
to the K201 connector, terminals 3 and 4. This thermistor is not used for defrost  
purposes on this model, but must be in place for proper operation of the control board.  
e) Energy Saving Mode  
"Energy Saving Mode" is not used on this unit. The "Energy Saving Mode" LED is  
located to the bottom right of the cabinet display and should be off. See "II.D.2. Control  
Board Layout." If the "Energy Saving Mode" LED is on, press the "SERVICE USE  
ONLY" button for 5 seconds to exit and disable the "Energy Saving Mode."  
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f) Temperature Correction Factor  
In cases where there is a discrepancy between the actual cabinet or rail temperature  
and the displayed temperature, a temperature correction factor is used to correct the  
displayed temperature.  
WARNING  
This unit has been factory tested with the default settings listed. Avoid using  
this function except to confirm that the setting is correct. If set incorrectly, the  
display could show an acceptable temperature even though the temperature  
is out of the proper range. This value should only be changed after consulting  
with the Hoshizaki Technical Support Department at 1-800-233-1940.  
To view the current values, move the power switch to the "ON" position while pressing  
the up arrow button. The current cabinet temperature correction factor will be shown. If  
"18" is displayed, the value is 1.8°F (1°C). Press the cabinet "SET" button to display the  
rail temperature correction factor.  
Temperature Correction Factor  
Default  
Area  
Setting Range  
1-Section  
2-Section  
3-Section  
TBD  
Cabinet  
Rail  
0°F (0°C)  
1.8°F (1°C) (0.9°F (0.5°C)  
-9 to 9°F in 0.9°F increments  
(-5 to 5°C in 0.5°C increments)  
TBD  
Negative values are indicated by an LED to the left of the value (Decimals are not  
shown on display)  
If it is determined through discussion with Hoshizaki Technical Support that the setting  
needs to be changed, follow the steps below.  
1) Display the cabinet or rail temperature correction factor as outlined above.  
2) Press the up or down button to increase or decrease the cabinet value.  
3) Press the cabinet "SET" button to save the new cabinet value.  
4) Press the cabinet "SET" button again to view the rail value.  
5) Press the up or down button to increase or decrease the rail value.  
6) Press the cabinet "SET" button to save the new rail value.  
7) Turn the power off and then back on. The unit will start running with the new value(s).  
[Example]  
When the actual cabinet temperature is 5.4°F (3°C) higher than the displayed temperature,  
change the temperature correction factor to 5.4°F (3°C), so that the displayed temperature  
matches the cabinet temperature.  
47.8°F (8.7°C)  
Actual Area Temperature  
5.4°F (3°C)  
Difference  
Displayed Temperature  
42.4°F (6°C)  
20  
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5. Service Menu  
The service menu ("F0" to "F9") may be used to change settings, acquire diagnostic  
information, and to view alarm history.  
To access the "F0" through "F9" service menu selections, you must first disconnect the  
service jumper (excluding "F5" which is accessible with or without the service jumper in  
place). The service jumper is located behind the wire cover below the control box and  
connects the control board K151 connector terminals 7 and 8 (white) together. When the  
service jumper is in place, only the "F5" selection is accessible. Be sure to reconnect the  
service jumper when finished.  
a) Service Menu Access  
• Enter Service Menu: Press and hold the cabinet "SET" button and the "SERVICE USE  
ONLY" button for 5 seconds. "F0" should appear in the display screen.  
• Scroll: Use the up and down arrow buttons to scroll through the service menu list,  
settings, and data.  
• View Service Menu Setting: Press the cabinet "SET" button to view the selected menu  
setting.  
• Save Setting: Press the cabinet "SET" button to save the new setting.  
• Return to Service Menu List: Press the cabinet "SET" button once again to return to the  
main service menu list.  
• Exit Service Menu: Press and hold the cabinet "SET" button and the "SERVICE  
USE ONLY" button for 5 seconds to exit the service menu at any time. If no button is  
pressed, the control board will return to the normal temperature display after 1 minute.  
"SET" buttons used to view current temperature settings.  
Cabinet "SET" button used with "SERVICE USE ONLY"  
button to enter and exit the service menu.  
"UP" and "DOWN" arrow buttons  
used to change temperature  
settings, scroll through the service  
menu, and to change menu settings.  
"SERVICE USE ONLY"  
button used with cabinet  
"SET" button to enter and  
exit the service menu.  
"MANUAL DEFROST"  
button used to initiate  
a manual defrost.  
21  
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b) Service Menu Chart  
Setting Range  
Cabinet  
1 to 12 hours in  
Factory Default  
Cabinet Rail  
N/A  
Service  
Menu  
Item and Details  
Defrost Interval  
Rail  
N/A  
F0  
6
1 hour increments.  
• The cabinet uses a time initiated  
heated defrost.  
• The change in the defrost  
interval setting will take effect  
immediately. The next defrost  
will take place after the newly  
set time interval has elapsed.  
• Initiating a manual defrost on the  
cabinet will restart the defrost  
timer.  
F1  
F2  
Defrost Termination Temperature  
Do not adjust. For  
recommendations, contact  
Hoshizaki Technical Support.  
Setpoint Temperature Differential Both the + and - values can be  
Use "SET" button to scroll through adjusted between 0 to 6.3°F in  
41 to 68°F  
(5 to 20°C)  
in 1 degree  
increments  
N/A  
49°F (9.4°C)  
N/A  
Comp on  
0°F (0°C)  
at setpoint  
Comp on  
0°F (0°C)  
at setpoint  
all 4 settings.  
increments of .9°F  
(0 to 3.5°C in increments of .5°C)  
(decimal not displayed)  
You cannot set both + and ‑ to  
Comp off  
-3.6°F (-2°C) -3.6°F (-2°C)  
below setpoint below setpoint  
Comp off  
0.0.  
• Negative value indicated by LED  
to left of number.  
F3  
F4  
High Temperature Alarm Delay  
Time: See "III.A. Alarm Signals."  
Low Temperature Alarm Delay  
Time: See "III.A. Alarm Signals."  
Temperature Display  
0 to 3 hours in 1 hour increments  
0 or 1 hour  
2
1
F5  
F6  
Fahrenheit or Celsius  
°F  
N/A  
Alarm History: maximum 8 alarms. Alarms displayed newest to oldest.  
When "‑‑" appears, you have  
No reset for alarm history  
available.  
Compressor Run Time (%):  
Displays compressor run time  
percentage between the 2 most  
recent defrosts.  
reached the end of the alarm  
history.  
N/A  
F7  
N/A  
N/A  
F8  
F9  
Not Used  
N/A  
Rail Cooling Switch:  
"LOW" Rail Fan Adjustment (rail  
section only)  
0=rail fans on continuously (same  
as "NORMAL" position)  
1=rail fans on 15 sec.  
rail fans off 90 sec.  
N/A  
2
2=rail fans on 1 sec.  
rail fans off 90 sec.  
FA  
High Condenser Temperature  
Adjustable between 140 to 167°F  
(60 to 75°C).  
140°F (60°C)  
(1 not displayed)  
Do not Alarm Setting (clogged filter):  
adjust For recommendations, contact  
Hoshizaki Technical Support.  
Fb  
Audible Control  
N/A  
N/A  
22  
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6. Alarm Signals  
In the event of operation outside of normal parameters, the control board identifies the  
issue with an alarm signal. The alarm signal and temperature are displayed in 1-second  
intervals. For service corrections, see "III.A. Alarm Signals."  
Alarm Signals  
E1  
E2  
E3  
E4  
High Temperature Alarm  
Low Temperature Alarm  
Defrost Alarm (cabinet only)  
Not Used  
High Condenser Temperature Alarm  
(clogged filter)  
E7  
E8  
E9  
Defrost Thermistor Malfunction Alarm  
Condenser Thermistor Malfunction Alarm  
EA EEPROM Write Error Alarm  
ED EEPROM Verification or Read Error Alarm  
7. Control Board Check Procedure  
Before replacing a control board that does not show a visible defect and that you  
suspect is bad, always conduct the following check procedure. This procedure will help  
you verify your diagnosis. Before you begin the diagnostics, verify proper supply voltage  
and that the unit is correctly plugged in.  
1) Move the power switch to the "ON" position and the rail switch to the "NORMAL"  
position. Both cabinet and rail temperatures should be displayed. The perimeter heater,  
cabinet fans, and rail fans should be on.  
2) If the temperature display is not on, check the 3A 125V fuse on the control board and  
the control transformer secondary circuit. Secondary transformer output is 10V at  
115V primary input. If the fuse and the secondary circuit voltage are good, but the  
temperature display is off, the control board is bad and should be replaced.  
3) If the temperature display is on and the components are not energizing, verify  
12VDC to the corresponding relay. If there is no voltage to the component relay, the  
control board is bad and should be replaced.  
8. Control Board Replacement  
1) Open the front panel. Move the power switch to the "OFF" position, then unplug the  
unit.  
2) Remove the wire cover, then remove the control box cover.  
3) Disconnect the control board wire connectors.  
4) Remove the control board.  
5) Install the new control board in the control box taking care not to damage it.  
6) Connect the control board wire connectors to the new control board.  
7) Replace the control box cover in its correct position.  
8) Plug in the unit, then move the power switch to the "ON" position to start the unit's  
cooling process.  
9) Check the setpoint and service menu settings and verify that they are set to the factory  
defaults. See "II.D.4. Controls and Adjustments" and "II.D.5. Service Menu."  
23  
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E.Thermistor Check  
Thermistors (semiconductors) are used for temperature control in the cabinet and  
rail areas, defrost termination, and for monitoring condenser temperature (clogged  
filter). The resistance varies depending on temperature. No adjustment is required.  
If necessary, check for resistance between thermistor leads and visually check the  
thermistor mounting.  
1) Disconnect the connector for the thermistor in question under the control box and  
behind the wire guard.  
2) Remove the thermistor. See "IV.H. Removal and Replacement of Thermistors and  
Thermostat."  
3) Immerse the thermistor portion in a glass or cup containing ice and water for 2 or  
3 minutes.  
4) Check for a resistance between thermistor leads. Normal reading is from 5 to 6.5 kΩ  
for the cabinet, rail, and defrost thermistors and 145 to 175 kΩ for the condenser  
thermistor. Replace the thermistor if it exceeds the normal reading.  
F. Perimeter Heater  
This unit is equipped with a perimeter heater. This prevents the formation of condensate  
on the frame of the unit under high humidity conditions. The unit incorporates a  
redundant perimeter heater in the event the main perimeter heater should fail.  
G. Compressor Protector  
When a combined temperature/amperage value is above the limit specified by the  
compressor manufacturer, a protector will operate independently, turning off the  
compressor. The compressor will restart when this protector has reset.  
Note:  
1. Compressor protector resets automatically.  
2. If the condenser fan is operating and the compressor is off, it is most likely that the  
protector has operated.  
24  
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III. Service Diagnosis  
WARNING  
1. This unit should be disassembled or repaired only by a qualified service  
technician to reduce the risk of injury, electric shock, or fire.  
2. Do not make any alterations to the unit. This could cause water leak, electric  
shock, or fire.  
3. To help reduce the risk of electric shock, do not touch the attachment plug or  
switches with damp hands.  
4. In case of insufficient refrigeration performance, move the stored food  
product into another unit to prevent its deterioration.  
A. Alarm Signals  
In the event of operation outside of normal parameters, the control board identifies the  
issue with an alarm signal. The alarm signal and cabinet temperature are displayed in  
1second intervals. For further service information, see "III.B. Service Chart." If multiple  
alarms occur simultaneously, only the alarm with the higher priority is displayed.  
Alarm  
Signal  
Priority Problem  
High Temperature Alarm (cabinet only)  
Reset, Corrections, and Adjustments  
When the temperature returns to the setpoint  
range, alarm resets.  
Cabinet temperature has exceeded the  
setpoint temperature by 18°F (10°C) for Close doors/drawers and clean the condenser and  
more than x hours. The default value of air filter. Check for refrigerant leaks. Check cabinet  
E1  
8
x is "2".  
thermistor.  
The value of x can be changed under "F3" on the  
Service Menu.  
(0=No delay; 1=1 hour; 2=2 hours; 3=3 hours)  
Low Temperature Alarm (cabinet only)  
Cabinet temperature has remained  
When the temperature returns to the setpoint  
range, alarm resets.  
below the setpoint by 9°F (5°C) for more Ambient temperature too low. Check thermistor,  
E2  
E3  
9
7
than y hours. The default value of y is  
"1".  
liquid line valve sticking, fans not operating.  
The value of y can be changed under "F4" on the  
Service Menu.  
(0=No delay; 1=hour)  
Defrost Alarm (cabinet only)  
Turn the power off, then back on.  
Cabinet defrost has taken longer than  
1 hour. The control board has terminated  
defrost.  
Check defrost heater, defrost thermistor.  
Note that "E3" may alternate with "dF" instead of  
the temperature.  
25  
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Alarm  
Signal  
Priority Problem  
High Condenser Temperature Alarm  
Reset, Corrections, and Adjustments  
Turn the power off, then back on.  
(clogged filter)  
Condenser and/or air filter dirty. Fan motor not  
turning. Possible restriction in refrigeration system.  
E7  
6
Condenser temperature is outside of  
normal operating temperature. 140°F  
(60°C)  
Failure to take action when this alarm activates  
could result in damage to the compressor.  
Defrost Thermistor Malfunction Alarm  
Defrost thermistor shorted or open.  
Condenser Thermistor Malfunction  
Alarm  
After replacing defrost thermistor, alarm resets.  
E8  
E9  
3
4
After replacing condenser thermistor, alarm resets.  
Condenser thermistor shorted or open.  
EEPROM Write Alarm  
After replacing control board, alarm resets.  
After replacing control board, alarm resets.  
EA  
ED  
2
1
Control board has failed.  
EEPROM Verification or Read Alarm  
Control board has failed.  
26  
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1. High Temperature Alarm (E1)  
If the cabinet or rail temperature exceeds the setpoint temperature by 18°F (10°C) or  
more for more than x hours, "E1" is displayed. The default value of x is "2" (2 hours).  
The value of x can be changed under "F3" on the service menu. (0=No delay; 1=1; 2=2;  
3=3 hours)  
Note:  
• After the machine has been turned off and then turned back on, the high  
temperature alarm feature is not active until the area temperature reaches the  
lower setpoint temperature differential.  
• The high temperature alarm feature operates even during defrost.  
Reset Options  
The alarm will automatically reset once the area temperature reaches the lower setpoint  
temperature differential.  
Possible Causes (for further details, see "III.B. Service Chart")  
• Doors or drawers are opened frequently or are not completely closed.  
Trouble with the compressor or a refrigerant leak.  
Trouble with the cabinet or rail thermistor.  
• Liquid line valve closed.  
Power On  
E1 Alarm not Available until  
Lower Setpoint is Achieved  
E1 Alarm Timer Reset  
E1 Alarm Timer  
over 2 hours  
E1 Alarm  
Timer under  
2 hours  
E1 Alarm  
E1 Alarm Temperature 18°F  
(10°C) above setpoint temp.  
Setpoint Temperature and  
Upper Setpoint Differential 0°F (0°C)  
E1 Alarm  
Available  
Lower Setpoint  
E1  
Alarm  
Reset  
Temperature Differential  
3.6°F (2°C)  
Temperature Display  
E1  
Blinking  
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2. Low Temperature Alarm (E2)  
If the cabinet or rail temperature drops below the setpoint temperature by 9°F (5°C) or  
more for more than y hours, "E2" is displayed. The default value of y is "1" (1 hour). The  
value of y can be changed under "F4" on the service menu. (0=No delay; 1=1 hour)  
Note:  
• The low temperature alarm timer starts once the cabinet temperature drops 9°F  
(5°C) below the setpoint temperature.  
• The low temperature alarm feature operates even during defrost.  
Reset Options  
The alarm will automatically reset once the area temperature reaches the upper setpoint  
temperature differential.  
Possible Causes (for further details see "III.B. Service Chart")  
• Ambient temperature is low.  
Trouble with the cabinet thermistor (black).  
• Liquid line valve open.  
• Evaporator fans not operating.  
Power On  
E2 Alarm Reset  
Setpoint Temperature and  
Upper Setpoint Differential 0°F (0°C)  
Lower Setpoint Temperature  
Differential -3.6°F (2°C)  
E2 Alarm Temperature  
9°F (5°C) below setpoint temp.  
E2 Alarm  
E2 Alarm Timer  
under 1 hour  
E2 Alarm  
Timer over  
1 hour  
E2 Alarm  
Timer Reset  
Temperature Display  
E2  
Blinking  
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3. Cabinet Defrost Alarm (E3)  
Once the defrost termination temperature is reached, the signal from the defrost  
thermistor should terminate the defrost. If the defrost thermistor does not terminate the  
defrost within 100 minutes (1 hour and 40 minutes), "E3" is displayed. When "E3" is  
displayed, the next step in the defrost process begins.  
Reset Options  
To reset the alarm, turn the power off and then back on.  
Possible Causes (for further details see "III.B. Service Chart")  
Trouble with the defrost heater.  
Trouble with the defrost thermistor.  
Trouble with the control board.  
29  
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4. High Condenser Temperature Alarm (clogged filter) (E7)  
The unit is equipped with a condenser air filter to protect the condenser from dirt, grease,  
etc. The condenser air filter promotes clean condenser surfaces and efficient operation  
and should be checked twice monthly and cleaned when necessary. The unit is also  
equipped with a condenser thermistor to determine if the condenser or condenser air  
filter is excessively dirty. If the condenser thermistor detects a temperature that exceeds  
the preset temperature value (136.4°F (58°C)) for over 2 minutes, "E7" will be displayed.  
CAUTION  
Failure to take action when this alarm activates could result in damage to the  
compressor.  
Reset Options  
After cleaning the filter, the alarm will automatically reset once the temperature at the  
condenser outlet drops below 136.4°F (58°C).  
Possible Causes (for further details see "III.B. Service Chart")  
• The condenser or condenser air filter is dirty.  
• The condenser fan motor is not functioning.  
Note: If the power is turned off and then back on while the alarm signal is displayed,  
the alarm may be reset even if the condenser or condenser air filter has not  
been cleaned. However, the alarm will repeat once the compressor discharge  
temperature reaches 136.4°F (58°C).  
E7 Alarm Timer Start  
2 min  
E7 Alarm  
Reset  
High  
E7 Alarm Temp.  
136.4°F (58°C)  
E7 Alarm  
Low  
Temperature Display  
E7 Alternating  
with Temperature  
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5. Defrost Thermistor (cabinet) Malfunction Alarm (E8)  
If the control board detects an open defrost thermistor, "E8" is displayed. When the  
control board detects a shorted defrost thermistor, a 10-minute delay timer begins. After  
the 10‑minute delay timer expires, "E8" is displayed. To bypass the 10‑minute delay  
timer, move the power switch to the "OFF" position. Then, while pressing the rail "SET"  
button, move the power switch to the "ON" position.  
• If this alarm appears, first make sure that the thermistor is properly connected to the  
control board.  
• A shorted defrost thermistor is not detected by the control board during the 1st hour  
after power is turned on. To bypass the 1-hour delay timer, move the power switch to  
the "OFF" position. Then, while pressing the rail "SET" button, move the power switch  
to the "ON" position.  
Reset Options  
The alarm automatically resets when one of the following conditions is met:  
• The defrost thermistor is secured to the control board.  
• The defrost thermistor is within normal operating range. For details, see "II.E. Thermistor  
Check."  
• A functioning defrost thermistor is installed.  
Possible Causes  
Trouble with the defrost thermistor. For checkout procedure, see "II.E. Thermistor Check."  
Trouble with the control board reading the defrost thermistor.  
E8 Alarm  
Timer Start  
E8 Alarm Timer Start  
10 min.  
Under 10 min.  
E8 Alarm (short circuit) Reset  
E8 (short circuit )  
Detection Point  
122°F (50°C)  
E8  
Alarm  
E8 Alarm  
(open circuit)  
Reset  
E8 Alarm (open circuit)  
Detection Point  
-67°F (-55°C)  
E8  
Alarm  
Temperature  
Display  
Temperature Display  
E8  
E8  
Blinking  
Blinking  
5a. Secondary Defrost Thermistor (Rail, not used)  
The secondary defrost thermistor (located behind the wire cover) is not used for  
operation of the unit. It is used for control board programming and should not be  
removed. An "E8" alarm occurs when the secondary defrost thermistor is removed or  
fails. For details, see "III.A.6. Defrost Thermistor (cabinet) Malfunction Alarm (E8)."  
31  
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6. Condenser Thermistor Malfunction Alarm (E9)  
If the control board detects an open condenser thermistor, "E9" is displayed. When the  
control board detects a shorted condenser thermistor, a 10-minute delay timer begins.  
After the 10‑minute delay timer expires, "E9" is displayed. To bypass the 10‑minute  
delay timer, move the power switch to the "OFF" position. Then, while pressing the rail  
"SET" button, move the power switch to the "ON" position.  
• If this alarm appears, first make sure that the thermistor is properly connected to the  
control board.  
• A shorted condenser thermistor is not detected by the control board during the 1st hour  
after power is turned on. To bypass the 1-hour delay timer, move the power switch to  
the "OFF" position. Then, while pressing the rail "SET" button, move the power switch  
to the "ON" position.  
Reset Options  
The "E9" alarm automatically resets when one of the following conditions is met:  
• The condenser thermistor is secured to the control board.  
• The condenser thermistor is within normal operating range. For details, see "II.  
E. Thermistor Check."  
• A functioning condenser thermistor is installed.  
Possible Causes  
Trouble with the condenser thermistor. For checkout procedure, see "II.E. Thermistor  
Check."  
Trouble with the control board reading the condenser thermistor.  
E9 Alarm  
E9 Alarm  
Timer Start  
Timer Start  
10 min.  
Under 10 min.  
E9 Alarm (short circuit) Reset  
E9 Alarm (short circuit)  
Detection Point  
186.8°F (86°C)  
E9 Alarm  
E9 Alarm (open circuit) Reset  
E9 Alarm (open circuit)  
Detection Point  
-7.6°F (-22°C)  
E9  
Alarm  
Temperature  
Display  
Temperature Display  
E9  
E9  
Blinking  
Blinking  
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7. Control Board Alarms (EA and ED)  
"EA" is displayed when an EEPROM write error is detected. "ED" is displayed when an  
EEPROM verification or read error is detected.  
Reset Options  
Replacing the control board with a functioning control board will eliminate this alarm  
condition.  
B. Service Chart  
1. No Operation  
Problem  
Possible Cause  
Remedy  
[1] The unit will not  
start.  
a)Power Supply  
1. Unplugged, off,  
blown fuse, or tripped  
or defective circuit  
breaker.  
1. Turn on, replace, or check  
and reset. Call electrician if  
breaker trips repeatedly.  
2. Loose connection.  
2. Tighten.  
3. Not within  
3. Refer to nameplate and  
correct.  
specifications.  
b)Cord and Plug  
c) Control Switch  
1. Defective.  
1. "OFF" position.  
2. Bad contacts.  
1. Replace.  
1. Move to "ON" position.  
2. Check for continuity and  
replace.  
d)Transformer  
1. Open coil winding.  
1. Check continuity and  
replace.  
e)Wiring to Control Board 1. Loose connections or 1. Check for continuity and  
open.  
replace.  
f) Control Board  
a)Fan Motor  
1. In alarm.  
2. Defective.  
1. Motor winding open.  
2. Bearing worn out.  
3. Wiring to fan motor.  
1. See "III.A. Alarm Signals."  
2. Replace.  
1. Replace.  
2 Replace.  
3. Check for loose or open  
connection, and replace.  
[2] Cabinet, rail, or  
condenser fan will  
not start.  
4. Fan blade bound.  
1. Bad contacts.  
4. Check and replace.  
1. Check for continuity and  
replace.  
2. Replace.  
1. Replace.  
b)Evaporator Fan, Rail  
Fan, or Compressor  
Relay  
2. Coil winding open.  
1. Defective.  
c) Control Board  
[3] Compressor will  
not start or stops  
operating.  
a)Compressor Relay  
1. Bad contacts.  
1. Check for continuity and  
replace.  
1. Check for continuity and  
replace.  
b)Compressor Control  
Relay  
1. Bad contacts.  
2. Open winding.  
1. Bad contacts.  
2. Coil winding open.  
1. Defective.  
2. Replace.  
1. Replace.  
2. Replace.  
1. Check and replace.  
1. Tighten.  
c) Start Relay  
d)Start Capacitor  
e)Wiring to Compressor 1. Loose connection(s).  
2. Faulty.  
2. Check continuity and  
replace.  
33  
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Problem  
Possible Cause  
Remedy  
[3] Compressor will  
not start or  
f) Voltage  
1. Too low.  
1. Call electrician.  
2. Call electrician.  
1. Move unit or increase  
ventilation.  
2. Too high.  
stops operating.  
(continued)  
g)High Pressure Switch 1. Restricted air flow to  
condenser.  
2. Condenser air filter  
and/or condenser  
clogged.  
2. Clean.  
3. Bad contacts.  
3. Check continuity and  
replace.  
4. Condenser fan motor. 4. See [2] a) and b).  
g)High Pressure Switch 5. Refrigerant line or  
5. Recover, remove  
(continued)  
component plugged or  
restricted.  
restriction, replace drier,  
evacuate, and recharge.  
6. Refrigerant overcharge. 6. Recover, evacuate, and  
recharge.  
7. Non-condensibles in  
system.  
7. Recover, replace drier,  
evacuate, and recharge.  
h)Thermistors (cabinet  
and rail)  
1. Defective.  
1. See "II.E. Thermistor  
Check."  
i) Compressor Overload 1. Defective. (open  
contacts)  
1. Replace.  
j) Compressor  
1. Open windings.  
1. Check for continuity and  
replace.  
2. Locked rotor.  
2. Replace.  
k) Control Board  
1. In alarm or defective.  
1. See "III.A. Alarm Signals"  
or replace  
2. Cabinet Cooling  
Problem  
Possible Cause  
Remedy  
[1] Cabinet  
temperature too  
high.  
a) Warm Food  
1. Warm food recently  
1. Pre-cool food or allow time  
placed in cabinet area. for unit to return to setpoint  
temperature.  
b) Doors/Drawers  
1. Left open, opened too 1. Close.  
often.  
2. Not sealing, opened  
frequently, or open for  
long intervals.  
2. Check for sealing, check for  
door open at time of warm  
cabinet temperature.  
c) Outside Heat Source  
d) Air Flow  
1. Too close to unit.  
1. Separate unit from heat  
source.  
1. Remove blockage by  
removing or redistributing  
food product.  
1. Blockage inside  
cabinet.  
e) Cabinet Thermistor  
1. Defective.  
1. Incorrect.  
1. See "II.E. Thermistor  
Check."  
f) Setpoint and/or  
Temperature  
1. Correct setting(s).  
See "II.D.4.c) Temperature  
Setpoint" or  
Correction Factor  
"II.D.4.f) Temperature  
Correction Factor" for  
defaults.  
34  
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Problem  
Possible Cause  
Remedy  
[1] Cabinet  
g) Defrost  
1. Defrost time  
1. See "4. Cabinet Defrost."  
temperature too  
high. (continued)  
insufficient to remove  
frost. Operation in  
humid conditions.  
2. Incomplete defrost.  
h) Air Filter or Condenser 1. Clogged, dirty.  
2. See "4. Cabinet Defrost."  
1. Clean.  
i) Cabinet Fan Motor  
j) Cabinet Liquid Line  
Valve  
1. Defective.  
1. Does not open.  
1. Check and replace.  
1. Check and replace.  
k) Service Valve(s)  
1. Partially or completely 1. Confirm service valve is  
closed.  
open.  
l) Refrigerant  
1. Leak.  
1. Recover, repair leak,  
replace drier, evacuate, and  
recharge.  
m) Expansion Valve  
n) Compressor  
1. Operating erratically. 1. Check and replace.  
1. Defective.  
1. See "1.[3] Compressor will  
not start or stops operating."  
o) Control Board  
[2] Cabinet temperature a) Setpoint and/or  
1. Defective.  
1. Incorrect.  
1. Replace.  
1. Correct setting(s).  
See "II.D.4.c) Temperature  
Setpoint" or  
too low.  
Temperature  
Correction Factor  
"II.D.4.f) Temperature  
Correction Factor" for  
defaults.  
b) Frozen Food  
1. Frozen food recently 1. Allow time for unit to return  
placed in refrigerator.  
1. Defective.  
1. Does not close.  
to setpoint temperature.  
1. Check and replace.  
1. Check and replace.  
c) Cabinet Thermistor  
d) Cabinet Liquid Line  
Valve  
e) Compressor Relay  
1. Defective; contacts  
welded.  
1. Replace.  
f) Control Board  
1. In alarm or defective. 1. See "III.A Alarm Signals" or  
replace.  
35  
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3. Rail Cooling  
Problem  
Possible Cause  
Remedy  
[1] Rail temperature too a) Warm Food  
high.  
1. Warm food recently  
placed in rail area.  
1. Pre-cool food or allow time  
for unit to return to setpoint  
temperature.  
b) Rail Pans/Dividers  
1. Missing, not in place. 1. Replace. Pans must cover  
entire rail for proper cooling.  
c) Outside Heat Source  
d) Rail Switch  
1. Too close to unit.  
1. "OFF" position.  
2. Bad contacts.  
1. Defective.  
1. Separate unit from heat  
source.  
1. Move to "NORMAL" or  
"LOW" position.  
2. Check for continuity and  
replace.  
e) Rail Thermistor  
1. See "II.E. Thermistor  
Check."  
f) Setpoint and/or  
Temperature  
1. Incorrect.  
1. Correct setting(s).  
See "II.D.4.c) Temperature  
Setpoint" or  
Correction Factor  
"II.D.4.f) Temperature  
Correction Factor" for  
defaults.  
g) Air Filter or Condenser 1. Clogged, dirty.  
h) Rail Liquid Line Valve 1. Does not open.  
1. Clean.  
1. Check and replace.  
i) Service Valve(s)  
1. Partially or completely 1. Confirm service valve is  
closed.  
open.  
j) Refrigerant  
1. Leak.  
1. Recover, repair leak,  
replace drier, evacuate, and  
recharge.  
k) Expansion Valve  
l) Compressor  
1. Operating erratically. 1. Check and replace.  
1. Defective.  
1. See "1.[3] Compressor will  
not start or stops operating."  
m)Control Board  
[2] Rail temperature too a) Setpoint and/or  
1. Defective.  
1. Incorrect.  
1. Replace.  
1. Correct setting(s).  
See "II.D.4.c) Temperature  
Setpoint" or  
low.  
Temperature  
Correction Factor  
"II.D.4.f)Temperature  
Correction Factor" for  
defaults.  
b) Frozen Food  
1. Frozen food recently 1. Allow time for unit to return  
placed in refrigerator.  
1. Defective.  
d) Rail Liquid Line Valve 1. Does not close.  
to setpoint temperature.  
1. Check and replace.  
1. Check and replace.  
1. Check and replace.  
1. Replace.  
c) Rail Thermistor  
e) Rail Fan Motor  
f) Control Board  
1. Defective.  
1. Defective.  
36  
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4. Cabinet Defrost  
Problem  
Possible Cause  
Remedy  
[1] Cabinet fan motors a) Cabinet Fan Relay  
on.  
1. Bad contacts (closed). 1. Check for continuity and  
replace.  
b) Control Board  
a) Defrost Thermistor  
1. Defective.  
1. Defective.  
1. Replace.  
1. See "II.E. Thermistor  
[2] Evaporator does  
not defrost  
Check."  
completely.  
b) Defrost  
1. Not enough defrosts 1. Factory default is once  
occurring per day.  
Operation in humid  
conditions.  
every 6 hours. See "II.D.5.  
Service Menu."  
c) Defrost Heater  
1. Defective.  
1. Replace heater.  
d) Defrost Thermostat  
1. Defective, turning off 1. Replace defrost thermostat.  
heaters prematurely,  
or fused open.  
e) Cabinet Liquid Line  
Valve  
1. Does not close.  
1. Check and replace.  
[3] Defrost cycle too  
long. (E3 Defrost  
Alarm)  
a) Defrost  
1. Not enough defrosts 1. Factory default is once  
occurring per day.  
Operation in humid  
conditions.  
every 6 hours. See "II.D.5  
Service Menu."  
b) Defrost Thermistor  
c) Defrost Heater  
1. Defective.  
1. Defective.  
1. Replace.  
1. Replace heater.  
d) Defrost Thermostat  
1. Defective, turning off 1. Replace defrost thermostat.  
heaters prematurely,  
or fused open.  
e) Control Board  
1. Defective.  
1. Replace.  
37  
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5. Other  
Problem  
Possible Cause  
Remedy  
[1] Condensate  
water overflow.  
a) Cabinet Contents  
1. Loading large volumes 1. Pre-cool food. Cover  
of warm, moist,  
product with plastic wrap.  
uncovered product.  
b) Location of Unit  
c) Seals  
1. Unit located near high 1. Relocate.  
humidity source such  
as fryer, steamer, etc.  
1. Poor sealing around  
evaporator, door/  
drawer gaskets.  
1. Adjust or replace.  
d) Environment  
1. Extreme environment 1. Adjust conditions.  
and door-opening  
conditions.  
e) Rail Condensate Pan  
a) Fasteners  
1. Overflowing.  
1. Empty and clean rail  
condensate pan.  
[2] Abnormal Noise  
1. Loose fasteners allow 1. Tighten fasteners.  
vibration of part.  
b) Compressor  
1. Problem with mount. 1. Properly mount  
compressor. Replace any  
missing grommets.  
2. Floodback to  
compressor.  
2. Check for signs of  
floodback to compressor.  
Recover, evacuate, and  
recharge if necessary.  
3. Defective.  
3. Replace.  
c) Fan  
1. Fan blade loose.  
2. Defective motor.  
1. Chattering.  
1. Loose.  
1. Adjust and tighten.  
2. Replace.  
1. Replace.  
d) Relay  
e) Liquid Line Valve  
Solenoid  
1. Tighten.  
38  
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IV. Removal and Replacement of Components  
WARNING  
1. This unit should be diagnosed and repaired only by qualified service  
personnel to reduce the risk of death, electric shock, serious injury, or fire.  
2. Move the power switch to the "OFF" position and unplug the unit before  
servicing.  
3. Make sure all food zones are clean after the unit is serviced. For cleaning  
procedures, see "V. Cleaning and Maintenance Instructions."  
A. Service for Refrigerant Lines  
WARNING  
1. Repairs requiring the refrigeration circuit to be opened must be performed by  
properly trained and EPA-certified service personnel.  
2. Always recover the refrigerant and store it in an approved container. Do not  
discharge the refrigerant into the atmosphere.  
3. Use an electronic leak detector or soap bubbles to check for leaks. Add a  
trace of refrigerant to the system (if using an electronic leak detector), and  
then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A  
as a mixture with pressurized air for leak testing.  
CAUTION  
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 drier every time the sealed refrigeration system is  
opened.  
3. Do not replace the drier until after all other repair or replacement has been  
made. Install the new drier with the arrow on the drier in the direction of the  
refrigerant flow.  
4. When brazing, protect the drier by using a wet cloth to prevent the drier from  
overheating. Do not allow the drier to exceed 250°F (121°C).  
5. Do not leave the system open for longer than 15 minutes when replacing or  
servicing parts.  
1. Refrigerant Recovery  
The unit is provided with a receiver service valve, and compressor and rail access  
valves. Using proper refrigerant practices, recover the refrigerant from the receiver  
service valve and compressor access valve and store it in an approved container. Do not  
discharge the refrigerant into the atmosphere.  
Note: Attach the high-side gauge manifold hose to the receiver service valve before  
opening the receiver service valve.  
39  
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2. Brazing  
WARNING  
1. R-404A itself is not flammable at atmospheric pressure and temperatures up  
to 176°F (80°C).  
2. R-404A itself is not explosive or poisonous. However, when exposed to high  
temperatures (open flames), these refrigerants can be decomposed to form  
hydrofluoric acid and carbonyl fluoride both of which are hazardous.  
3. Do not use silver alloy or copper alloy containing arsenic.  
4. Use an electronic leak detector or soap bubbles to check for leaks. Add a  
trace of refrigerant to the system (if using an electronic leak detector), and  
then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A  
as a mixture with pressurized air for leak testing.  
1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
Note: Because the pipes in the evaporator case are specially coated to resist corrosion,  
it is important to make connections outside the evaporator case when possible. If  
it is necessary to braze inside the evaporator case, use sandpaper to remove the  
coating from the brazing connections before unbrazing the components.  
CAUTION  
1. Always install a new drier every time the sealed refrigeration system is  
opened.  
2. Do not replace the drier until after all other repair or replacement has been  
made. Install the new drier with the arrow on the drier in the direction of the  
refrigerant flow.  
3. When brazing, protect the drier by using a wet cloth to prevent the drier from  
overheating. Do not allow the drier to exceed 250°F (121°C).  
2) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of  
refrigerant to the system (if using an electronic leak detector), and then raise the  
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with  
pressurized air for leak testing.  
3. Evacuation and Recharge (R-404A)  
1) Attach a vacuum pump to the system. Be sure to connect the gauge manifold hoses to  
the receiver service valve (high-side) and the compressor access valve (low-side). For  
high-side system access, run in the receiver service valve stem a couple of turns.  
IMPORTANT  
The vacuum pump may be the same as those for current refrigerants.  
However, the rubber hose and gauge manifold to be used for evacuation and  
refrigerant charge should be exclusively for POE oils.  
2) Turn on the vacuum pump. Open the gauge manifold valves. Never allow the oil in the  
vacuum pump to flow backwards.  
40  
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3) Allow the vacuum pump to pull down to a 29.9" Hg vacuum. Evacuating period depends  
on pump capacity.  
4) Close both gauge manifold valves.  
5) Turn off the vacuum pump. Disconnect the vacuum pump hose and attach it to a  
refrigerant service cylinder. 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 (latest edition) be used.  
6) A liquid charge is recommended for charging an R-404A system. Invert the service  
cylinder and place it on scales.  
7) Open the high-side gauge manifold valve and allow the system to charge with liquid  
until the proper charge is met.  
8) If necessary, add any remaining charge to the system through the compressor access  
valve. Use a throttling valve or liquid dispensing device to add the remaining liquid  
charge through the compressor access valve with the unit running.  
9) Back out the receiver service valve stem all the way and tighten. Disconnect the gauge  
manifold hoses.  
Note: Be sure the receiver service valve stem is backseated all the way out and tight  
before disconnecting the gauge manifold hose.  
10) Cap the valves to prevent possible leaks.  
Upper Attachment Nut  
and Washer  
Power Cord  
Power Switch  
Rail Liquid Line Valve  
Rail Cooling Switch  
Lower Attachment Nut  
and Washer  
Wire Cover  
Receiver Service Valve  
Condenser  
Compressor  
Receiver Tank  
Drier  
Hex Head Bolt  
Rail Expansion Valve  
Cabinet Liquid Line Valve  
Cabinet Expansion Valve  
Rail Low-Side  
Access Valve  
Rail Low-Side Service Valve  
Rail High-Side  
Access Valve  
Rail Service Valve Bracket  
Rail High-Side Service Valve  
Compressor  
Access Valve  
Rail Refrigerant Tubes  
Fig. 1  
41  
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B. Removal and Replacement of Refrigeration System Cartridge  
CAUTION  
The refrigeration system cartridge should not be removed until the refrigerant  
has been properly recovered or the refrigeration system has been properly  
pumped down. For refrigeration system repairs, the refrigerant recovery  
procedure must be used. See "IV.B.1. Refrigerant Recovery Procedure." For  
non‑refrigeration system repairs, see "IV.B.2. Pump‑Down Procedure." Do not  
discharge the refrigerant into the atmosphere.  
1. Refrigerant Recovery Procedure  
1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the  
unit.  
2) Remove the left side panel.  
3) Connect the gauge manifold hoses to the receiver service valve (high-side) and the  
compressor access valve (low-side). See Fig. 1.  
4) Run in the receiver service valve stem a couple of turns for high-side system access.  
Note: Be sure the high-side gauge manifold hose is on the receiver service valve  
before opening the receiver service valve.  
5) Using proper refrigerant practices, recover the refrigerant and store it in an approved  
container. Do not discharge the refrigerant into the atmosphere.  
6) When the recovery is finished, close the gauge manifold valves and back out the  
receiver service valve stem all the way and tighten.  
Note: Be sure the receiver service valve stem is backseated all the way out and tight.  
7) Close the rail high and low-side service valves. Run in the rail service valve stems all  
the way until tight.  
Note: Be sure the rail high and low-side service valve stems are seated all the way in  
and tight.  
8) Disconnect the rail refrigerant tubes from the rail service valves. Use a backup wrench  
when loosening the fittings. See Fig. 1.  
9) Remove the screw securing the rail service valve bracket.  
10) Disconnect the power supply cord connector, rail thermistor connector, and the  
perimeter heater/rail fan motor connector.  
11) Remove the wire cover below the control box.  
12) Remove the upper and lower attachment nuts and washers from the control box and  
the hex head bolt from the base of the refrigeration cartridge. See Fig. 1.  
42  
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13) Slide the refrigeration cartridge forward. Support the evaporator as it clears the  
evaporator case. See Fig. 2.  
CAUTION  
1. Be careful when handling the cabinet evaporator assembly. This assembly  
includes a defrost heater sheathed in a glass tube. This sheathing can be  
easily damaged and may also cause cuts if broken. The defrost heater will  
also be hot after a defrost. Use gloves when handling and avoid touching the  
glass directly. Also prevent the defrost heater from touching other parts.  
2. To avoid refrigerant leaks, be sure to prevent the refrigeration piping from  
coming into contact with the frame when removing and replacing the  
refrigeration cartridge.  
14) Once the repair is made, replace the refrigeration cartridge back into its correct  
position. Support the cabinet evaporator as it enters the cabinet evaporator case.  
15) Reconnect the rail refrigerant tubes. Use a backup wrench and tighten the fittings 1/6  
turn beyond fully seated. Be sure to use a backup wrench when tightening the fittings.  
16) Secure the rail service valve bracket back in its correct position.  
17) Secure the refrigeration cartridge with the attachment nuts, washers, and the hex head  
bolt.  
18) Replace the wire cover and panels in their correct positions.  
19) Open the rail high and low-side service valves. Back out the rail service valve stems all  
the way to their original position and tighten.  
Note: Be sure the rail high and low-side service valve stems are backseated all the way  
out and tight.  
20) Run in the receiver service valve stem a couple of turns for high-side system access.  
Note: Be sure the high-side gauge manifold hose is on the receiver service valve  
before opening the receiver service valve.  
21) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of  
refrigerant to the system (if using an electronic leak detector), and then raise the  
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with  
pressurized air for leak testing.  
22) Evacuate the system. Then, charge the system with refrigerant; see the nameplate for  
the required refrigerant charge.  
23) Back out the receiver service valve stem all the way and tighten, then close both gauge  
manifold valves.  
Note: Be sure the receiver service valve stem is backseated all the way out and tight.  
24) Cap the valves to prevent a possible leak.  
25) Reconnect the power supply cord connector, rail thermistor connector, and perimeter  
heater/rail fan motor connector.  
26) Plug the unit back in, then move the power switch to the "ON" position to start the unit's  
cooling process.  
43  
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2. Refrigeration System Pump-Down Procedure  
1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the  
unit.  
2) Remove the left side panel.  
3) Connect the gauge manifold hoses to the receiver service valve (high-side) and the rail  
low-side access valve. See Fig. 1.  
Note: Be sure the high-side gauge manifold hose is on the receiver service valve  
before opening the receiver service valve.  
4) Run in the receiver service valve stem all the way until tight.  
Note: Be sure the receiver service valve stem is seated all the way in and tight.  
5) Plug the unit back in, then move the power switch to the "ON" position.  
6) Move the rail switch to the "NORMAL" position. There is a 2‑minute delay before the  
compressor starts. Once the compressor starts, the system pump-down begins.  
7) When the low-side gauge indicates a vacuum, close the high and low-side rail service  
valves completely. Run in the rail service valve stems all the way until tight.  
Note: Be sure the rail high and low-side service valve stems are seated all the way in  
and tight.  
8) Move the power switch to the "OFF" position, then unplug the unit.  
9) Back out the receiver service valve stem all the way until fully seated. Remove the  
high-side gauge manifold hose.  
Note: Be sure the receiver service valve stem is backseated all the way out and tight.  
10) Use a backup wrench and disconnect the rail refrigerant tubes from the rail high and  
low-side service valves. Use a backup wrench when loosening the fittings. See Fig. 1.  
11) Remove the screw securing the rail service valve bracket.  
12) Disconnect the power supply cord connector, rail thermistor connector, and perimeter  
heater/rail fan connector.  
13) Remove the wire cover below the control box.  
14) Remove the upper and lower attachment nuts and washers from the control box and  
the hex head bolt from the base of the refrigeration system cartridge. See Fig. 1.  
15) Slide the refrigeration cartridge forward. Support the evaporator as it clears the  
evaporator case. See Fig. 2.  
CAUTION  
1. Be careful when handling the cabinet evaporator assembly. This assembly  
includes a defrost heater sheathed in a glass tube. This sheathing can be  
easily damaged and may also cause cuts if broken. The defrost heater will  
also be hot after a defrost. Use gloves when handling and avoid touching the  
glass directly. Also prevent the defrost heater from touching other parts.  
2. To avoid refrigerant leaks, be sure to prevent the refrigeration piping from  
coming into contact with the frame when removing and replacing the  
refrigeration cartridge.  
44  
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16) Once the repair is made, replace the refrigeration cartridge back into its correct  
position. Support the cabinet evaporator as it enters the cabinet evaporator case.  
17) Reconnect the rail side refrigerant tubes. Use a backup wrench and tighten the fittings  
1/6 turn beyond fully seated. Use a backup wrench when tightening the fittings.  
18) Secure the rail service valve bracket back in its correct position.  
19) Secure the refrigeration cartridge with the attachment nuts, washers, and the hex head  
bolt.  
20) Replace the wire cover and panels in their correct positions.  
21) Connect the high-side gauge manifold hose to the rail high-side access valve.  
22) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of  
refrigerant to the system (if using an electronic leak detector), and then raise the  
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with  
pressurized air for leak testing  
23) Evacuate the rail system. Close the gauge manifold valves.  
24) Open the rail high and low-side service valves. Back out the rail high and low-side  
service valve stems all the way until fully seated.  
Note: Be sure the rail high and low-side service valve stems are backseated all the way  
out and tight.  
25) Remove the gauge manifold hoses.  
26) Cap the valves to prevent possible refrigerant leaks.  
27) Use an electronic leak detector or soap bubbles to check the rail refrigerant  
connections for refrigerant leaks.  
28) Reconnect the power supply cord connector, rail thermistor connector, and the  
perimeter heater/rail fan connector.  
29) Plug the unit back in, then move the power switch to the "ON" position to start the unit's  
cooling process.  
45  
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46  
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C. Removal and Replacement of Compressor  
CAUTION  
1. Always install a new drier every time the sealed refrigeration system is  
opened.  
2. Do not replace the drier until after all other repair or replacement has been  
made. Install the new drier with the arrow on the drier in the direction of the  
refrigerant flow.  
3. When brazing, protect the drier by using a wet cloth to prevent the drier from  
overheating. Do not allow the drier to exceed 250°F (121°C).  
4. Recover the refrigerant when replacing the compressor. Do not discharge  
the refrigerant into the atmosphere.  
5. The compressor may be replaced without removing the refrigeration  
cartridge. If removing the refrigeration cartridge, see "IV.B. Removal and  
Replacement of Refrigeration Cartridge."  
Note: When replacing a compressor with a defective winding, be sure to install a new  
start capacitor, overload and start relay. Due to the ability of the POE oil in the  
compressor 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 the same type of refrigerant,  
except when they use the same lubricant.  
1) Move the power switch to the "OFF" position, then unplug the unit.  
2) Remove the front, left side, and rear panels.  
3) Recover the refrigerant and store it in an approved container.  
4) Remove the terminal cover on the compressor and disconnect the compressor wiring.  
5) Remove the discharge, process, and suction pipes.  
6) Remove the hold-down bolts, washers, rubber grommets, and sleeves.  
7) Remove the compressor. Unpack the new compressor. Attach the rubber grommets  
and sleeves of the prior compressor.  
8) Place the new compressor in position, and secure it using the bolts and washers.  
9) Remove the drier, then place the new drier in position.  
10) Remove the plugs from the suction, discharge, and process pipes.  
11) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
12) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of  
refrigerant to the system (if using an electronic leak detector), and then raise the  
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with  
pressurized air for leak testing.  
13) Evacuate the system, and charge it with refrigerant; see the nameplate for the required  
refrigerant charge.  
14) Connect the compressor terminals, then replace the terminal cover in its correct  
position.  
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15) Replace the panels in their correct positions.  
16) Plug in the unit, then move the power switch to the "ON" position to start the unit's  
cooling process.  
D. Removal and Replacement of Cabinet Evaporator  
CAUTION  
1. Always install a new drier every time the sealed refrigeration system is  
opened.  
2. Do not replace the drier until after all other repair or replacement has been  
made. Install the new drier with the arrow on the drier in the direction of the  
refrigerant flow.  
3. When brazing, protect the drier by using a wet cloth to prevent the drier from  
overheating. Do not allow the drier to exceed 250°F (121°C).  
1) Remove the refrigeration system cartridge. Perform steps 1 through 14 in "IV.B.1.  
Recovery Procedure." Once the refrigeration cartridge is out, proceed to step 2.  
WARNING  
Be careful when handling the cabinet evaporator assembly. This assembly  
includes a defrost heater sheathed in a glass tube. This sheathing can be  
easily damaged and may also cause cuts if broken. The defrost heater will also  
be hot after a defrost. Use gloves when handling and avoid touching the glass  
directly. Also prevent the defrost heater from touching other parts.  
2) Remove the defrost heater, defrost thermostat, defrost and cabinet thermistors from the  
evaporator. See Fig. 3.  
3) Remove the evaporator shroud and evaporator bracket from the evaporator.  
4) Remove the insulation tubing, and disconnect the evaporator inlet and outlet tubing.  
5) Remove the screws holding the evaporator to the refrigeration system cartridge.  
6) Remove the evaporator and drier.  
7) Place the new evaporator and new drier in position. Provide a safe means for  
supporting the evaporator.  
Evaporator Shroud  
Defrost Thermistor  
Evaporator Bracket  
Cabinet Fan Motors  
Defrost Thermostat  
Defrost Heater  
Evaporator  
Cabinet Thermistor Bracket  
Cabinet Thermistor  
Fig. 3  
48  
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8) Braze the fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
9) Replace the removed evaporator parts in their correct positions.  
10) Once the repair is complete, return to step 15 in "IV.B.1. Recovery Procedure" for  
refrigeration system cartridge replacement.  
E. Removal and Replacement of Expansion Valve  
Moisture in the refrigeration circuit may exceed drier capacity and freeze up at the  
expansion valve.  
CAUTION  
1. Always install a new drier every time the sealed refrigeration system is  
opened.  
2. Do not replace the drier until after all other repair or replacement has been  
made. Install the new drier with the arrow on the drier in the direction of the  
refrigerant flow.  
3. When brazing, protect the valve body and drier by using wet cloths to  
prevent the valve body and drier from overheating. Do not allow the valve  
body or drier to exceed 250°F (121°C).  
1) Move the power switch to the "OFF" position, then unplug the unit.  
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. Place the new  
expansion valve in position.  
6) Remove the drier, then place the new drier in position.  
7) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
8) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of  
refrigerant to the system (if using an electronic leak detector), and then raise the  
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with  
pressurized air for leak testing.  
9) Evacuate the system and charge it with refrigerant; see the nameplate for the required  
refrigerant charge.  
10) Attach the expansion valve bulb to the suction line in the same location as the previous  
bulb. The bulb should be between the 10 and 2 o'clock position on the tube. Be sure to  
secure the bulb with the clamp and holder and to insulate it.  
11) Place the expansion valve cover in position.  
12) Replace the panels in their correct positions.  
13) Plug in the unit, then move the power switch to the "ON" position to start the unit's  
cooling process.  
49  
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F. Removal and Replacement of Liquid Line Valve  
CAUTION  
1. Always install a new drier every time the sealed refrigeration system is  
opened.  
2. Do not replace the drier until after all other repair or replacement has been  
made. Install the new drier with the arrow on the drier in the direction of the  
refrigerant flow.  
3. When brazing, protect the valve body and drier by using wet cloths to  
prevent the valve body and drier from overheating. Do not allow the valve  
body or drier to exceed 250°F (121°C).  
1) Move the power switch to the "OFF" position, then unplug the unit.  
2) Remove the panels.  
3) Recover the refrigerant and store it in an approved container.  
4) Remove the bolt and the solenoid.  
5) Disconnect the valve.  
6) Place the new valve in position.  
7) Remove the drier, then place the new drier in position.  
8) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
9) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of  
refrigerant to the system (if using an electronic leak detector), and then raise the  
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with  
pressurized air for leak testing.  
10) Evacuate the system and charge it with refrigerant; see the nameplate for the required  
refrigerant charge.  
11) Cut the leads of the solenoid allowing enough lead length to reconnect using closed  
end connectors.  
12) Connect the new solenoid leads.  
13) Attach the solenoid to the valve body and secure it with the bolt.  
14) Replace the panels in their correct positions.  
15) Plug in the unit, then move the power switch to the "ON" position to start the unit's  
cooling process.  
50  
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G. Removal and Replacement of Condenser  
CAUTION  
1. Always install a new drier every time the sealed refrigeration system is  
opened.  
2. Do not replace the drier until after all other repair or replacement has been  
made. Install the new drier with the arrow on the drier in the direction of the  
refrigerant flow.  
3. When brazing, protect the drier by using a wet cloth to prevent the drier from  
overheating. Do not allow the drier to exceed 250°F (121°C).  
1) Move the power switch to the "OFF" position, then unplug the unit.  
2) Remove the panels.  
3) Remove the refrigeration system cartridge. Perform steps 1 through 14 in "IV.B.1.  
Recovery Procedure." Once the refrigeration system cartridge is out, proceed to step 4.  
4) Remove the condenser thermistor (clogged filter).  
5) Disconnect the condenser inlet and outlet piping.  
6) Remove the condenser assembly.  
7) Remove the air guide, evaporator case cover bracket, and condenser shroud (A) from  
the old condenser and attach it to the new condenser. See Fig. 4.  
8) Place the new condenser assembly in position.  
9) Remove the drier, then place the new drier in position.  
10) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.  
11) Replace the condenser thermistor (clogged filter) in its correct position.  
12) Once the repair is complete, return to step 15 in "IV.B.1. Recovery Procedure" for  
refrigeration system cartridge replacement.  
Evaporator Case  
Cover Bracket  
Condenser  
Condenser Shroud (A)  
Air Guide  
Condenser Thermistor  
(clogged filter)  
Fig. 4  
51  
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H. Removal and Replacement of Thermistors and Thermostat  
CAUTION  
1. The thermistors are fragile; handle very carefully.  
2. Do not shorten or cut the thermistor leads.  
1. Cabinet Thermistor  
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.  
Pump‑Down Procedure." Once the refrigeration system cartridge is out, proceed to  
step 2.  
2) Cut the cable tie holding the cabinet thermistor to the cabinet thermistor bracket.  
Remove the thermistor. See Fig. 5.  
3) Disconnect the thermistor wire connector (below the control box).  
4) Install the new thermistor and secure it to the cabinet thermistor bracket. Connect the  
thermistor connector.  
5) Once the repair is complete, return to step 17 in "IV.B.2. Pump‑Down Procedure" for  
refrigeration system cartridge replacement.  
2. Defrost Thermistor  
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.  
Pump‑Down Procedure." Once the refrigeration system cartridge is out, proceed to step  
2.  
2) Remove the tape securing the defrost thermistor to the evaporator shroud. Cut the  
cable tie holding the defrost thermistor to the shroud. Remove the defrost thermistor.  
See Fig. 5.  
3) Disconnect the defrost thermistor wire connector (below the control box).  
4) Install the new defrost thermistor and secure to the evaporator shroud. Connect the  
defrost thermistor connector.  
5) Once the repair is complete, return to step 17 in "IV.B.2. Pump‑Down Procedure" for  
refrigeration system cartridge replacement.  
Defrost Thermistor  
Cabinet Fan  
Motors  
Defrost Thermostat  
Evaporator Shroud  
Defrost Heater  
Cabinet Thermistor Bracket  
Fig. 5  
Cabinet Thermistor  
52  
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3. Defrost Thermostat  
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.  
Pump‑Down Procedure." Once the refrigeration system cartridge is out, proceed to  
step 2.  
2) Disconnect the defrost thermostat wires, then remove the defrost thermostat.  
See Fig. 5.  
3) Install the new defrost thermostat and connect the thermostat wires.  
4) Once the repair is complete, return to step 17 in "IV.B.2. Pump‑Down Procedure" for  
refrigeration system cartridge replacement.  
4. Rail Thermistor  
1) Open the front panel. Move the power switch to the "OFF" position, then unplug the  
unit.  
2) Remove the storage pans from the rail area. If wet, dry the rail area with a dry cloth.  
3) Remove the left side rail fan motor shroud. See Fig. 6.  
4) Cut the ties securing the rail thermistor to the bracket.  
5) Secure the new thermistor connector to the old thermistor in the rail area. DO NOT cut  
the new thermistor wire.  
6) Remove the wire access hole sealant and grommet.  
7) Push the old thermistor wire (with new thermistor wire securely attached) into the  
rail channel. Once the new thermistor wire is in the channel, replace the access hole  
grommet. Remove the left side panel, then pull the thermistor wire through the rail  
channel.  
Rail Fan Motor  
Rail Fan Motor  
Shroud  
Bracket  
Rail Fan Motor  
Rail Thermistor  
Rail Thermistor  
Fig. 6  
8) Disconnect the old thermistor connector from the control box connector, then connect  
the new thermistor connector to the control box connector.  
9) Secure the new rail thermistor to the bracket with a cable tie.  
10) Seal the access hole with food grade silicone.  
11) Replace the rail fan motor shroud in its correct position and secure. Make sure all wires  
are clear of the fan.  
12) Replace the panel and empty storage pans in their correct positions.  
13) Plug in the unit, then move the power switch to the "ON" position and the rail switch to  
the "NORMAL" position to start the unit's cooling process.  
14) Do not place food product in the rail area until the rail section has cooled down.  
53  
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5. Condenser Thermistor (clogged filter)  
1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the  
unit.  
2) Remove the left side panel.  
3) Remove the aluminum tape and cut the cable tie securing the thermistor. See Fig. 7.  
4) Remove the thermistor. Disconnect the wire connection (below the control box).  
5) Install the new thermistor and secure with a cable tie and aluminum tape.  
6) Plug in the unit, then move the power switch to the "ON" position to start the unit's  
cooling process.  
Condenser Thermistor  
(clogged filter)  
Fig. 7  
I. Removal and Replacement of Defrost Heater  
CAUTION  
Be careful when handling both the old and new defrost heaters. The heaters  
are sheathed in glass tubes and can possibly cause cuts if broken. The heater  
will also be hot after a defrost. Use gloves when handling. Avoid touching the  
glass directly; hold the heaters by the ends.  
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.  
Pump‑Down Procedure." Once the refrigeration system cartridge is out, proceed to  
step 2.  
2) Remove the defrost heater from the defrost heater bracket. See Fig. 8.  
3) Disconnect the defrost heater wires.  
4) Carefully remove the defrost heater.  
5) Place the new defrost heater into position.  
6) Connect the new defrost heater wires.  
7) Once the repair is complete, return to step  
17 in "IV.B.2. Pump‑Down Procedure" for  
refrigeration system cartridge replacement.  
Defrost Heater Bracket  
Defrost Heater  
Fig. 8  
54  
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J. Removal and Replacement of Fan Motors  
1. Cabinet Fan Motor  
CAUTION  
Be careful when handling the evaporator shroud assembly. This assembly  
includes a defrost heater sheathed in a glass tube. This sheathing can be  
easily damaged and may also cause cuts if broken. Heater will also be hot after  
a defrost. Use gloves when handling and avoid touching the glass directly. Also  
prevent heaters from touching other parts.  
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.  
Pump‑Down Procedure." Once the refrigeration system cartridge is out, return to  
step 2.  
2) Disconnect the wires to the fan motor, then remove the defrost thermistor, cabinet  
thermistor, defrost thermostat, and defrost heater from the evaporator shroud.  
3) Remove the evaporator shroud from the evaporator.  
4) Remove the fan motor. See Fig. 9.  
5) Install the new fan motor.  
Note: Confirm that the fan motor wires are sealed with food grade silicone at the motor  
housing.  
6) Replace the evaporator shroud in its proper position.  
7) Replace the removed parts in their correct positions, and connect the fan motor wires.  
8) Once the repair is complete, return to step 17 in "IV.B.2. Pump‑Down Procedure" for  
refrigeration system cartridge replacement.  
Cabinet Fan  
Motors  
Evaporator Shroud  
Defrost Thermistor  
Cabinet Fan Motors  
Defrost Thermostat  
Defrost Heater  
Fig. 9  
Cabinet Thermistor  
55  
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2. Condenser Fan Motor  
1) Open the front panel. Move the power switch to the "OFF" position, then unplug the  
unit.  
2) Remove the left side panel.  
3) Disconnect the fan motor wires.  
4) Remove the condenser fan motor assembly bolts, then remove the condenser fan  
motor assembly. See Fig. 10.  
5) Remove the fan motor from the fan motor bracket and remove the fan blade from the  
fan motor.  
6) Place the fan blade on the new fan motor, then install the new fan motor.  
7) Replace the fan motor assembly in its correct position.  
8) Connect the fan motor wires.  
9) Replace the panels in their correct positions.  
10) Plug in the unit, then move the power switch to the "ON" position to start the unit's  
cooling process.  
Condenser Fan Blade  
Condenser Fan Motor  
Condenser Fan  
Motor Bracket  
Condenser  
Fig. 10  
3. Rail Fan Motor  
1) Open the front panel. Move the power switch to the "OFF" position, then unplug the  
unit.  
2) Remove the storage pans from the rail area. If wet, dry the rail area with a dry cloth.  
3) Remove the rail fan motor shroud. See Fig. 11.  
4) Disconnect the rail fan motor lead wires at least 6" (15 cm) from the fan motor. Remove  
the rail fan motor and bracket.  
5) Remove the rail fan motor bracket from the old rail fan motor and place on the new rail  
fan motor.  
6) Secure the new fan motor wires to the old fan motor wires in the rail area. DO NOT cut  
the new fan motor wires.  
56  
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7) Remove the rail access hole sealant and grommet.  
8) Push the old fan motor wires (with new fan motor wires securely attached) into the rail  
channel. Once the new fan motor wires are in the channel, replace the access hole  
grommet. Remove the left side panel, then pull the fan motor wires through the rail  
channel.  
9) Disconnect and discard the old fan motor wires. Connect the new fan motor wires.  
10) Seal the rail access hole with food grade silicone.  
11) Place the new rail fan motor and the fan motor shroud in their correct positions and  
secure. Make sure all wires are clear of the fan.  
12) Replace the panel and empty storage pans in their correct positions.  
13) Plug in the unit, then move the power switch to the "ON" position and the rail switch to  
the "NORMAL" position to start the unit's cooling process.  
14) Do not place food products in the rail area until the rail section has cooled down.  
Rail Fan Motor  
Rail Fan Motor Shroud  
Rail Fan Motor Bracket  
Fig. 11  
K. Removal and Replacement of Door Gasket  
Remove the old gasket by pulling it directly out of the vinyl gasket retainer. Thoroughly  
clean the gasket area with mild soap and water prior to installing the new gasket. The  
new gasket should be installed at the corners first, then working toward the center at  
the top, bottom, and sides. The arrow-shaped portion of the gasket should be firmly  
seated in the retainer groove for proper assembly. This can be checked by lifting the  
edge of the gasket and observing the engagement.  
CAUTION  
In order to get a proper gasket fit, it is important not to stretch gasket material  
during assembly.  
L. Door Re-Hinging and Drawer Conversion  
Contact your local Hoshizaki distributor or Hoshizaki Technical Support if door reversing  
or drawer conversion is desired.  
57  
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V. Cleaning and Maintenance Instructions  
A. Cleaning  
WARNING  
1. Before cleaning the unit, move the power switch to the "OFF" position and  
unplug the unit to prevent electric shock by unexpected entrance of water  
into the unit or injury by moving parts.  
2. Before cleaning the unit, move all foods into another clean refrigerator or  
freezer.  
3. Do not splash water directly onto the unit. This might cause short circuit,  
electric shock, corrosion, or failure.  
4. Do not pour or spray water into the rail area. The rail drain is for condensate  
only. Excessive liquid in the rail area could result in electric shock. Be sure to  
keep the fans dry.  
5. Metal edges can cause cuts. Use care and wear protective gloves when  
cleaning.  
6. Keep hands clear of fan shrouds when the unit is operating. The rotating fans  
might cause injury.  
7. Before using a sanitizer such as inert soap and sodium hypochlorite (chlorine  
bleach), thoroughly read the manufacturer’s instructions on its proper usage.  
IMPORTANT  
1. To prevent damage to the painted or plastic surfaces, do not use the  
following: thinner, benzine, alcohol, petroleum, soap powder, polishing  
powder, alkaline cleaner, acid, scouring pad, and especially those strong  
cleaners for use on a ventilating fan or a cooking range. Also, to prevent  
corrosion, do not use a chlorine bleach such as sodium hypochlorite on the  
stainless steel surfaces.  
2. Use a clean cloth for cleaning.  
1. Work Surface  
Clean the cutting board as often as necessary to maintain a clean, sanitary work surface.  
Also clean the worktop space underneath the cutting board as often as necessary to  
maintain a clean, sanitary surface. After cleaning, be sure to properly secure the cutting  
board with the brackets on the ends of the worktop. Slide the brackets down onto the  
cutting board and tighten the screws.  
WARNING  
Make sure the cutting board is secure. Otherwise, the cutting board could come  
off and cause injury.  
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2. Rail and Rail Cover  
Spills and splashes should be wiped up promptly to avoid unpleasant odors. Wipe  
the interior of the rail and the rail cover regularly with a clean, damp sponge or cloth  
containing a neutral cleaner. Do not pour or spray water into the rail area.  
WARNING  
1. Be sure to support the rail cover when cleaning. Otherwise, the rail cover  
could close suddenly and cause injury.  
2. Metal edges can cause cuts. Use care and wear protective gloves when  
cleaning.  
3. Exterior  
Wipe the exterior occasionally with a clean, soft cloth. Use a damp cloth containing a  
neutral cleaner to wipe off oil or dirt build up.  
4. Cabinet Interior  
Spills and splashes should be wiped up promptly to avoid unpleasant odors. The  
cabinet interior should be cleaned periodically with a mild soap or detergent and warm  
water.  
5. Door/Drawer Gaskets  
Door/drawer gaskets should be cleaned regularly with mild soap and warm water to  
remove dirt and grease.  
6. Shelves (if applicable)  
Remove and clean regularly.  
7. Drawers (if applicable)  
The drawers can be removed for cleaning either individually or as an entire assembly.  
To remove an individual drawer, first remove all food product from the drawer. Pull  
the drawer out to its fully extended position and lift up on the handle to disengage the  
drawer. Before removing the drawer, carefully support the rear and front of the drawer  
and then slowly remove it from the cabinet.  
To remove the drawer frame assembly, rst remove the drawers and then remove  
the fasteners in the thermal break and in the rear of the cabinet. Carefully slide the  
frame out of the cabinet, making sure not to damage the thermal break. Reinstall in the  
reverse order, making sure not to overtighten the screws in the thermal break.  
To remove the drawer slide (center slide containing rollers) for cleaning, rotate the top  
of the slide away from the frame while the slide is completely inside the cabinet. Drawer  
slides do not require lubrication, but slides should be kept clean and free of food.  
Note: Drawer slides are dishwasher safe.  
59  
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B. Maintenance  
1. Rail Condensate Pan  
The rail condensate pan collects condensate water from the rail. Empty the pan as often  
as necessary depending on conditions. Clean the pan at least once a month with a  
clean, damp sponge or cloth containing a neutral cleaner.  
2. Air Filter  
The plastic mesh air filter (located behind the front panel) removes dirt and dust from  
the air, and keeps the condenser from getting clogged. As the filter gets clogged,  
the unit'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. The filter can be  
removed by opening the front panel and lifting the filter away from the condenser.  
3. Condenser  
Check the condenser once a year, and clean if required by following the steps below.  
More frequent cleaning may be required depending on location.  
WARNING  
1. Before cleaning the condenser, move the power switch to the "OFF" position  
and unplug the unit to prevent electric shock or injury by moving parts.  
2. Before cleaning the condenser, move all foods into another clean refrigerator  
or freezer.  
3. Condenser fins are sharp. Use care when cleaning.  
1) Remove and clean the air filter.  
2) Use a brush attachment on a vacuum cleaner to gently clean the condenser fins. Do  
not use too much force, otherwise the fins could be damaged.  
3) Replace the air filter in its proper position.  
4. Power Supply Connection  
If the plug or power cord is damaged, contact a Hoshizaki Certified Service  
Representative immediately and ask for repairs.  
All other maintenance or service on this unit should be performed in accordance with  
the Hoshizaki Service Manual by a qualified service technician.  
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C. Shutdown and Long Storage  
WARNING  
1. When preparing the unit for long storage, prevent the doors/drawers from  
closing to reduce the risk of children getting trapped.  
2. To reduce the risk of electric shock, do not touch the attachment plug or  
switches with damp hands.  
3. To unplug the unit, be sure to pull the attachment plug and do not jerk the  
power cord. It could be damaged and cause fire or electric shock.  
4. When shutting down the unit for more than one week, move the power  
switch to the "OFF" position and unplug the unit.  
5. Do not plug in/unplug the unit to start/stop operation. Make sure the power  
switch is in the "OFF" position before plugging in or unplugging the unit to  
help reduce the risk of electric shock.  
1) Before shutting down the unit, move food into another refrigerator or freezer.  
2) Open the front panel and move the power switch to the "OFF" position. The unit will  
shut down.  
3) Unplug the unit.  
4) Close the front panel.  
IMPORTANT  
When preparing the unit for long storage, perform the cleaning and  
maintenance operations detailed in "V. Cleaning and Maintenance  
Instructions."  
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VI.Technical Information  
A. Refrigeration Circuit  
1. HPR46A(-D), HPR72A(-D), HPR100A(-D)  
62  
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B. Wiring Diagrams  
1. HPR46A(-D)  
Transformer Output  
10V at 115V  
*
*High Pressure Switch  
Cut-out 490 10PSIG  
Cut-in  
370 20 PSIG  
63  
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2a. HPR72A(-D) Auxiliary Code U-5 and Earlier  
Transformer Output  
10V at 115V  
*
*High Pressure Switch  
Cut-out 490 10PSIG  
Cut-in 370 20 PSIG  
64  
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2b. HPR72A(-D) Auxiliary Code U-6 and Later  
Transformer Output  
10V at 115V  
*
*High Pressure Switch  
Cut-out 490 10PSIG  
Cut-in  
370 20 PSIG  
65  
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3. HPR100A(-D)  
AWAITING DATA  
66  
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