Service Manual Cubelet Icemaker/Dispenser Models DCM-270BAH(-OS) F-A & F-C Control Boards hoshizakiamerica.
WARNING Only qualified service technicians should install and service the icemaker. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit www.hoshizaki.com. No service should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.
IMPORTANT This manual should be read carefully before the appliance is serviced. Read the warnings and guidelines contained in this booklet carefully as they provide essential information for the continued safe use, service, and maintenance of the appliance. Retain this booklet for any further reference that may be necessary. CONTENTS Important Safety Information.................................................................................................. 4 I.
Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury. NOTICE Indicates a situation which could result in damage to the appliance or property. IMPORTANT Indicates important information about the use and care of the appliance.
WARNING, continued • Do not make any alterations to the appliance. Alterations could result in electric shock, injury, fire, or damage to the appliance. • Do not place fingers or any other objects into the ice discharge opening.
I. Construction and Water Refrigeration Circuit Diagrams A. Construction 1.
B.
C. "F-C" Dip Switch 8 and 9 "OFF" *1-min. or 5-min. Comp energized FM energized GM energized UFS open LFS open FT starts (90 sec.) WV energized Comp energized FM energized GM energized 2. Icemaker Off Comp energized FM energized GM energized to "2. Ice Purge Cycle" above if UFS closed. to "1. Fill Cycle" above if UFS open. 4. Icemaker Restart to "2. Ice Purge Cycle" above if UFS closed. to "1. Fill Cycle" above if UFS open.
B. Service Diagnosis WARNING • The appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Risk of electric shock. Use extreme caution and exercise safe electrical practices. • Moving parts (e.g., fan blade) can crush and cut. Keep hands clear. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the appliance is serviced.
2. Diagnostic Procedure The diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components. Before proceeding, check for correct installation, adequate water pressure (10 to 113 PSIG), and proper voltage per unit nameplate. Note: • When checking high voltage (115VAC), always choose a neutral (W) wire to establish a good neutral connection. • When checking low voltage (24VAC), always choose a neutral (LBU) wire.
4) Fill Cycle – "WTRIN" LED is on. WV energizes. The 90-sec. low water safety timer begins. LFS closes. Nothing occurs at this time. The reservoir continues to fill until UFS closes, terminating the 90‑sec. low water safety timer, starting the 30‑min. freeze timer, and de-energizing WV. Diagnosis: Check that "WTRIN" LED turns on and water fills the reservoir. If not, check for water supply line shut‑off valve closed, restricted water filters, and restricted WV screen.
6) Freeze Cycle – "COMP" LED is on. ice purge timer terminates (1‑min. "F-A" CB E-0 (H) and later and "F-C" CB dip switch 8 off or 5-min. "F-A" CB E-0 (G) and earlier dip switch 8 on) or the "SERVICE" button is pressed. "COMP" LED turns on. "GM" LED remains on. Comp and FM energize. GM and CCR continue. Ice production begins 4 to 6 minutes after Comp energizes depending on ambient and water conditions. Diagnosis Comp: Check that "COMP" LED is on and that Comp energizes.
10) Shutdown a) "F-A" E-0 (H) and Earlier Dip Switch 8 "ON" CB Shutdown – Bin fills with ice activating BC micro-switch. Within 6 to 10 sec. CB shutsdown appliance. b) "F-A" E-0 (H) and Later Dip Switch 8 "OFF" Shutdown – Bin fills with ice activating BC micro-switch. CB starts 90‑sec. Comp shutdown timer. Once 90‑sec. Comp shutdown timer terminates, Comp and FM de‑energize and 60‑sec. GM shutdown timer starts. Once 60-sec. GM shutdown timer terminates, GM de‑energizes and icemaker is off.
C. Control Board Check Before replacing a CB 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 proceeding, check for proper voltage per appliance nameplate. Check that the 24VAC 1A fuse is good and 115VAC 3A GM external protector is closed. NOTICE! Control Board Change: • "F-A" control board 2A4296-01 no longer available. • "F-C" control board 2A8054-01 new and replaces 2A4296-01.
1) Startup-"POWER OK" LED on: Move control switch to "ICE" position, then move power switch to "ON" position. "POWER OK" LED turns on. "POWER" LED remains on unless power supply is interrupted. Diagnosis: Check that "POWER OK" LED is on. If not, check for proper 115VAC supply voltage to CT (main breaker or fuse and power switch). Next, check for proper 24VAC output from CT. Next, check that 1A fuse is good. Check for 24VAC from CB K8 connector pin #1 (W/R) to CB K8 connector pin #2 (LBU).
2a) 5VDC CB K9 Connector Continued: a) Control Switch"DRAIN" Position CB K9 connector pins #1 (W/BK) and #2 (W/BK): • "ICE" Position: When the control switch is in the "ICE" position, CB K9 connector pin #1 and pin #2 are open. 5VDC is present between CB K9 connector pin #1 (W/BK) and pin #2 (W/BK). If not, check control switch position and continuity (open). Replace as needed. Next, confirm 5VDC between pin #1 (W/BK) and CB red K4 connector, pin closest to CB black K3 connector.
2b) 5VDC CB K8 Connector: See Fig. 2.
2c) 5VDC CB K7 Connector: See Figs. 3, 4, 5, and 6. a) Water Dispense 1. Push Button Model CB K7 connector pins #3 (W/BK) and #8 (Y) or (P): "WTRDP" LED is on: Before engaging the water dispense switch, check for the correct VDC from the locations given in the "Disengaged" column in the table below. If the VDC is different than in the table, replace CB. If the VDC is correct, engage the water dispense switch. "WTRDP" LED turns on.
2. Opti-Serve Model CB K8 connector pins #7 (R), #8 (Y) or (P), and #9 (BK): Before engaging the water dispense OS sensor, check for the correct VDC from the locations given in the "Disengaged" column in the table below. If the VDC is different than in the table, replace CB. If the VDC is correct, engage the OS sensor. "WTRDP" LED turns on. If not, confirm that the water dispense signal VDC matches the "Engaged" column in the table below. If not, replace the OS sensor.
b) Ice Dispense 1. Push Button Model CB K7 connector pins #2 (Y) and #3 (W/BK): "ICE" and "AM" LEDs are on: Before engaging the ice dispense switch, check for the correct VDC from the locations given in the "Disengaged" column in the table below. If the VDC is different than in the table, replace CB. If the VDC is correct, engage the ice dispense switch. "ICE" LED turns on. If not, check the ice dispense switch continuity when engaged (closed). If the ice dispense switch is open when engaged, replace.
2. Opti-Serve Model CB K8 connector pins #1 (W/R), #2 (Y), and #3 (W/BK): Before engaging the ice dispense OS sensor, check for the correct VDC from the locations given in the "Disengaged" column in the table below. If the VDC is different than in the table, replace CB. If the VDC reading is correct, engage the OS sensor. "ICE" LED turns on. If not, confirm that the ice dispense signal VDC matches the "Engaged" column in the table below. If not, replace the OS sensor.
3) Fill Cycle–"WTRIN" LED is on: "WTRIN" LED turns on only when the reservoir water level is low enough to open LFS. Diagnosis: Confirm LFS is open. If "WTRIN" LED is off and LFS is open and the control switch is in the "ICE" position (open), replace CB. If "WTRIN" LED is on and water is not filling the reservoir, check for 24VAC at CB K2 connector between pin #8 (O) and neutral (LBU).
D. Bin Control Check When BC (micro-switch) is not engaged, BC circuit (CB K8 #3 (GY) and CB K8 #4 (GY)) is closed and the appliance produces ice. When ice fills the bin and engages BC large balance plate, BC opens. NOTICE! Do not place S1 dip switch 7 or S1 dip switch 8 out of the factory default position. These dip switches must be left in the factory default position or the appliance will not operate correctly. For details, see "III.C.1. Default Dip Switch Settings.
13) a. "F-A" CB E-0 (G) and Earlier Dip Switch 8 "ON": Comp and GM should de‑energize within 10 seconds. b. "F-A" CB E-0 (H) and Later Dip Switch 8 "OFF": 90-sec. Comp shutdown timer starts. Once 90-sec. Comp shutdown timer terminates, Comp and FM de‑energize and 60‑sec. GM shutdown timer starts. Once 60-sec. GM shutdown timer terminates, GM de‑energizes. c. "F-C" CB dip switch 8 and 9 "OFF": 90-sec. Comp shutdown timer starts. Once 90‑sec. Comp shutdown timer terminates, Comp and FM de‑energize and 60‑sec.
E. Float Switch Check and Cleaning 1. Float Switch Check 1) Remove the front, top, and left side panels, then move the control switch to the "DRAIN" position. 2) After the water has drained from the reservoir, remove the FS molex plug from the control box and check continuity across FS wires. Common (BK) to UFS (R) and common (BK) to LFS (BU). See Fig. 7. With the reservoir empty, float switches are open. If open, continue to step 3. If closed, follow the steps in "II.E.2. Float Switch Cleaning.
Red (R) (upper float switch) Black (BK) (common) Blue (BU) (lower float switch) Magnet (towards top) Upper Float (blue) Spring Retainer Clip Magnet (towards top) Lower Float (white) Plastic Retainer Clip Fig. 7 Float Switch Assembly Reservoir Cover Reservoir Fig.
F. Diagnostic Tables Before consulting the diagnostic tables, check for correct installation, proper voltage per appliance nameplate, and adequate water pressure (10 to 113 PSIG). Check control board using the steps in "II.C. Control Board Check." 1. No Ice Production No Ice Production - Possible Cause Startup 1. Power Supply a) Unplugged, off, blown fuse, tripped or defective circuit breaker. b) Loose connection. c) Not within specifications. 2. Cord and Plug a) Loose connection. b) Defective. 3.
No Ice Production - Possible Cause Ice Purge Cycle 1. Control Board a) No power to gear motor. 2. Gear Motor a) 3A external protector tripped. b) Internal protector open. c) Motor winding. d) Mechanical failure. 3. Coupling a) Defective. 4. Compressor Control Relay a) Defective. Freeze Cycle 1. Control Board a) No power to compressor control relay circuit (5VDC) or not reading circuit. 2. Start Relay a) Defective. 3. Start Capacitor a) Defective. 4. Compressor a) External protector.
No Ice Production - Possible Cause Refill 1. Water Supply a) Off. 2. Control Board a) No power to float switch (5VDC) or not reading float switch condition. b) No power to inlet water valve (24VAC). 3. Float Switch a) Float does not move freely. b) Defective. 4. Inlet Water Valve a) Clogged or defective. Shutdown 1. Bin Control a) Large balance plate sticking. b) Micro-switch defective. 2. Control Board a) S1 dip switch settings not set correctly. b) Defective. 2.
Water Dispense-Push Button 1. Power Supply a) Off, blown fuse, or tripped breaker. 2. Control Board a) No power from control board to water dispense switch (5VDC) or not reading signal. b) No power to dispense water valve (24VAC). 3. Water Dispense Switch a) Defective. 4. Water Dispense Valve a) Water supply turned off. b) Defective. Water Dispense-Opti-Serve 1. Power Supply a) Off, blown fuse, or tripped breaker. 2.
III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in DCM series appliances. • All models are pre-tested and factory adjusted. • For a control board check procedure, see "II.C. Control Board Check." NOTICE • The control board is fragile; handle very carefully. • The control board contains integrated circuits, which are susceptible to failure due to static discharge.
A. Control Board Layout 1.
2.
B. LED Lights and Audible Alarm Safeties The "POWER" LED indicates proper control voltage and will remain on unless a control voltage problem occurs. For further details, see "II. B. Service Diagnosis." Sequence Step LED Fill Cycle WTRIN Ice Purge Cycle Freeze Cycle (with refill) 1-1 hr or 1-12 hr Drain Cycle GM GM, WTRIN* (refill), COMP FLUSH (Drain) Do not adjust for 1-in12 on this model.
C. Settings and Adjustments 1. Default Dip Switch Settings The S1 dip switch settings are factory-set to the following positions: Dip Switch No. Control Board & Aux.
4. Continuous Dispensing Timer (S1 dip switch 5 & 6) The factory setting allows ice to be dispensed continuously for 20 sec. The DCM-270BAH may be adjusted to other dispense time options. NOTICE! On DCM-270BAH-OS, do not adjust S1 dip switch 5 & 6 out of the factory default position. S1 Dip Switch Setting Dispense Time No. 5 No. 6 OFF OFF No Limit ON OFF 20 Seconds OFF ON 60 Seconds ON ON No Limit Note: The ice dispense solenoid has an internal overload protector.
7. Bin Control Shutdown Delay (S1 dip switch 9) (F-C CB Only) The shutdown delay is the time between the bin control micro-switch opening and the control board shutting down the appliance. WARNING! Do not adjust S1 dip switch 9 out of the factory default position. This dip switch must be left in the factory default position or the appliance will not operate correctly. S1 Dip Switch Setting Bin Control Shutdown Delay No. 9 "F-C" CB OFF 90-60 Second Sequence (150 sec. total) ON 6 to 10 Seconds 8.
IV. Refrigeration Circuit and Component Service Information WARNING • This appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Move the power switch to the "OFF" position, then unplug the appliance from the electrical outlet before servicing. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced.
2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). • R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R-404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous. • Do not use silver alloy or copper alloy containing arsenic. • Use an electronic leak detector or soap bubbles to check for leaks.
5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. Remember to loosen the connection and purge the air from the hose. See the rating label inside the icemaker for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used. 6) A liquid charge is required for charging an R-404A system (to prevent fractionation).
B. Component Service Information NOTICE • When replacing a component listed below, see the notes to help ensure proper operation. • When replacing evaporator assembly and water circuit components, make sure there are no water leaks after the repair is complete. • Seal bolts must be replaced once removed because seal material is one-time use only. If new seal bolts do not have preapplied threadlocker, apply Loctite 243 or equivalent threadlocker to seal bolt threads.
Icemaking Unit Cutter/Agitator Extruding Head (Upper Bearing) Drip Ring Auger Cover O-Ring Seal Bolt Evaporator Socket Head Cap Screw Ring Mechanical Seal O-Ring Housing (Lower Bearing) Gear Motor Spline Coupling Socket Head Cap Screw Fig.
C. Icemaking Unit 1. Upper Bearing Wear Check To ensure that the bearing inside the extruding head does not exceed the wear tolerance of .02", follow the instructions below. See Fig. 3. 1) Move the control switch to the "OFF" position, then turn off the power supply. Remove the front and top panels, then move the power switch to the "OFF" position. 2) Remove the top of the storage bin, then remove the agitator by turning it counter clockwise. Next, lift the drip pan out of the storage bin area.
2. Removal and Replacement of Extruding Head 1) Move the control switch to the "DRAIN" position and drain all of the water from the evaporator. 2) After the water has stopped draining, move the control switch to the "OFF" position, then turn off the power supply. Remove the front and top panels, then move the power switch to the "OFF" position. 3) Remove the front cover of the storage bin. Remove spout B, then remove spout A and the cutter. See Fig. 2.
4. Removal and Replacement of Evaporator NOTICE • Always install a new drier every time the sealed refrigeration system is opened. • Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant flow. • 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).
15) 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. 16) Evacuate the system, and charge it with refrigerant. See the nameplate for the required refrigerant charge.
5b. Lower Housing 11) Remove the O-ring and the bolts securing the housing to the gear motor and remove the housing from the gear motor. If inspection of the upper bearing inside the extruding head (see "IV.C.1. Upper Bearing Wear Check") indicates that it is out of tolerance, replace both it and the bearing inside the lower housing. Note: Replacing the bearing requires a bearing press adaptor. If one is not available, replace the whole extruding head and housing.
6. Removal and Replacement of Gear Motor 1) Move the control switch to the "DRAIN" position and drain all of the water from the evaporator. 2) After the water has stopped draining, move the control switch to the "OFF" position, then turn off the power supply. Remove the front and top panels, then move the power switch to the "OFF" position. 3) Remove the front cover of the storage bin. Remove spout B, then remove spout A. See Fig. 2. 4) Remove the apron panel, then remove the left side panel.
V. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the appliance's environment, and local sanitation regulations. WARNING • Only qualified service technicians should service the appliance.
VI. Preparing the Appliance for Periods of Non-Use NOTICE When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. When the appliance is not used for two or three days under normal conditions, it is sufficient to only move the power switch to the "OFF" position. When storing the appliance for extended time or in sub-freezing temperatures, follow the instructions below.
VII. Disposal This appliance contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.
VIII. Technical Information We reserve the right to make changes in specifications and design without prior notice. A. Specification and Performance Data Sheets Pressure data is recorded at 5 min. into freezing cycle. The data not in bold should be used for reference only. 1. DCM-270BAH SPECIFICATION SHEET AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.
2. DCM-270BAH-OS SPECIFICATION SHEET AC SUPPLY VOLTAGE AMPERAGE MAXIMUM FUSE SIZE MINIMUM CIRCUIT AMPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) APPROXIMATE STORAGE CAPACITY REFRIGERANT CHARGE WEIGHT PERFORMANCE DATA APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg/day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. (TOTAL) gal. / day (l/day) EVAPORATOR OUTLET TEMP.
B. Wiring Diagrams 1. DCM-270BAH(-OS): Serial Number: C10508L to D00829A (except C17634M and C17641M) (BR) (W) GR 115/60/1 N L BR COMPRESSOR CONTROL RELAY BR W/O W/O BK 1 2 3 4 5 6 7 8 W W START CAP. 145-174MFD START RELAY GY W W 1 2 3 4 BK GY EXTERNAL PROTECTOR 6 BR 7 8 W BR CAP.
2.
