Hoshizaki Hoshizaki America, Inc. Cubelet Icemaker/Dispenser Models DCM-300BAH(-OS) “A Superior Degree of Reliability” SERVICE MANUAL www.hoshizaki.
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 icemaker 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 icemaker 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 icemaker. Retain this booklet for any further reference that may be necessary. CONTENTS Important Safety Information.................................................................................................. 5 I. Specifications..............................
IV. Service Diagnosis............................................................................................................ 21 A. Ice Production Check................................................................................................... 21 B. Diagnostic Procedure................................................................................................... 21 C. Control Board Check....................................................................................................
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.
NOTICE • Follow the instructions in this manual carefully to reduce the risk of costly water damage. • In areas where water damage is a concern, install in a contained area with a floor drain. • Install the icemaker in a location that stays above freezing. Normal operating ambient temperature must be within 45°F to 100°F (7°C to 38°C). • Do not leave the icemaker on during extended periods of non-use, extended absences, or in sub-freezing temperatures.
I. Specifications A. Icemaker 1. DCM-300BAH(-OS) AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR AGITATING MOTOR DISPENSING MOTOR OTHER MAXIMUM FUSE SIZE MAX. HACR BREAKER (USA ONLY) MAX. CIRC. BREAKER (CANADA ONLY) MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg/day) Reference without *marks SHAPE OF ICE ICE HARDNESS FACTOR APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER gal./24HR (gal./100 lbs.
II. General Information A. Construction 1.
2.
B. Sequence of Operation 1. Sequence Cycles and Shutdown The steps in the sequence are as outlined below. When power is supplied, power switch is in the "ON" position, safety switch is engaged, and the control switch is in the "ICE" position, CB "POWER" LED turns on. The "POWER" LED indicates control voltage and will remain on unless a control voltage problem occurs. If icemaker does not start, BC actuator and proximity switch may be engaged.
12-Hr. Drain Cycle DCT terminates DVT starts GM continues Comp de-energizes FM de-energizes 60 sec. 60 sec. DV energizes GM de-energized 2. Drain 3. Icemaker Restart BC closed WV continues until UF/S closes Legend: BC-bin control CB-control board Comp-compressor DCT-drain cycle timer (12-hr. timer) DV-drain valve DVT-drain valve timer (20-min. timer) FM-fan motor FT-fill timer (90-sec.
C. Control Board • A Hoshizaki exclusive control board is employed in Hoshizaki icemakers. • All models are pre-tested and factory adjusted. • For a control board check procedure, see "IV.C. Control Board Check Procedure." NOTICE • The control board is fragile; handle very carefully. • 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 icemaker before handling or replacing the control board.
1. Control Board Layout a) DCM-300BAH "DCM-PB" Push Button Model Control Board • Ice Dispense Time Control • Counter Reset Button (not used in this application) • Relay LEDs (red) (indicate which relays and connector pins are energized) • "FLUSH" (drain) Switch (Do not adjust) • K3 Connector #3 24VAC Output to Control Switch, Inlet Water Valve, Water Control Relay, and Drain Valve • "FLUSH" (drain) LED (X5 Relay) K2 Connector Pin #8 12-hr.
b) DCM-300BAH-OS "DCM-OS" Opti-Serve Model Control Board • Ice Dispense Time Control • "FLUSH" (drain) LED (X6 Relay) K2 Connector Pin #10 12-hr.
2. LED Lights and Components The "POWER" LED indicates control voltage and will remain on unless a control voltage problem occurs. For further details, see "II.B. Sequence of Operation." GM GM, COMP Icemaking Energized Components WV GM GM, Comp, FM Time LEDs are Frequency LEDs are On On N/A N/A 60 sec. N/A N/A N/A FLUSH (drain) DV 20 min.
2. Control Switch The control switch is a double-pole double-throw switch with 3 positions, "ICE," "OFF," and "DRAIN." a) ICE When the control switch is in the "ICE" position, the control switch directs 5VDC from control board K4 connector pin #3 to control board K4 connector pin #4. When the control board receives 5VDC on K4 connector pin #4, the icemaking process starts.
III. Technical Information A.
B. Wiring Diagrams 1.
2.
C. Performance Data 1. DCM-300BAH(-OS) APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg/day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. gal./day l/day EVAPORATOR OUTLET TEMP Ambient Temp. (°F) 70 80 90 100 70 80 90 100 321 277 237 203 653 656 660 671 70 80 40 35 152 131 38 33 145 124 36 31 138 118 90 30 112 29 110 27 101 100 25 96 24 91 23 86 50 146 125 107 92 ----- Water Temp.
IV. Service Diagnosis WARNING • This icemaker 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 icemaker is serviced.
7) Startup – Move the power switch to the "ON" position, then move the control switch to the "ICE" position to start the automatic icemaking process. Diagnosis: Check that CB "POWER" LED is on. If not, check for proper power supply voltage (115VAC) input to CT. If 115VAC is not present, check the breaker, power switch, and front panel safety switch. Next, check that the power protect relay is de‑energized and contacts between terminals #6 (BR wire) and #2 (BK wire) are closed.
9) Ice Purge Cycle – "GM" LED is on. GM and GMPR energize. 60-sec. ice purge timer starts. GM runs for 60 sec. to clear any ice from the evaporator. Note: GM cannot energize unless UF/S is closed, WCR is energized, and WCR terminals #4 (O wire) and #6 (GY wire) are closed. Diagnosis: If "GM" LED is off, check control switch and BC continuity. If either are open, CB "GM" LED will not turn on. If both are closed and CB "GM" LED does not turn on, replace CB.
12) Drain Cycle – "FLUSH" (drain) LED is on. The icemaker drains the evaporator and reservoir once every 12 hr. A manual drain is provided when cleaning the icemaker by moving the control switch from the "ICE" position to the "DRAIN" position. a) Automatic Drain Cycle: A drain cycle occurs once every 12 hr. for 20 min. DCT terminates and DVT starts. If the icemaker is not running when DCT terminates, DV energizes immediately. If the icemaker is running when DCT terminates, Comp and FM de-energize.
if defective. If 24VAC is present, check for 24VAC at GMPR terminal #2 (P wire) to a neutral (LBU wire). If 24VAC is not present, check GMPR continuity between terminals #2 (P wire) and #6 (LBU wire). If open, replace GMPR. Next, check for 24VAC at DV. If 24VAC is present and DV does not energize, check DV solenoid continuity. 13) Shutdown – Bin fills with ice and activates BC actuator paddle. 150-sec. shutdown sequence begins. 90 sec. after BC opens, Comp and FM de-energize, AM energizes for 0.6 sec.
C. Control Board Check Before replacing CB that does not show a visible defect and that you suspect is bad, conduct the following CB check. This procedure will help you verify your diagnosis. Before proceeding, check for proper voltage per unit nameplate. Check that the 24VAC 1A fuse, 10.5VAC 0.5A CT fuse are good, and the 115VAC GM external protector is not tripped. When checking high-voltage (115VAC), always choose a neutral (W wire) to establish a good neutral connection.
• Icemaking Control Circuit: The icemaking control circuit consists of WCR, CS, and BC. The icemaking control circuit activates once UF/S closes. Once CB reads a closed circuit through WCR, CS, and BC, CB then starts the 60-sec. ice purge cycle (GM operation). Once UF/S closes, WCR energizes, closing contacts between WCR terminals #4 (GY wire) and #6 (O wire). CS must be in the "ICE" position (O wires).
b) Opti-Serve Model – "ICE" and "AM" LEDs are on: (1) "CONTINUOUS" Mode: Before engaging the ice dispense Opti-Serve sensor, check for 5VDC from the locations given in the table below. If VDC is different than in the table, replace CB. If VDC is correct, engage the Opti-Serve sensor and confirm that VDC matches the table below. If not, see "IV.F.3a. Ice Dispense "CONTINUOUS" Mode" to rule out a faulty Opti-Serve sensor. If the Opti‑Serve sensor checks out, replace CB.
• Water Dispense Switch/Water Dispense Sensor a) Push Button Model: The water dispense button and DispWV are not associated with CB. Engage the water dispense button, then check for 24VAC at DispWV. If 24VAC is present and no water is dispensed, check for water supply line shut-off valve closed, clogged water filters, clogged WV screen. If the water supply is good, replace DispWV. If 24VAC is not present, check water dispense switch continuity and CT 24VAC fuse, 125VAC power supply, and continuity.
8) Drain Cycle – "FLUSH" (drain) LED is on: 12-hr. DCT terminates or CS is moved to "DRAIN" position. 150-sec. shutdown sequence starts. 90 seconds later, Comp de‑energizes and Comp LED turns off. 60 seconds after Comp de-energizes, GM de‑energizes and GM LED turns off. Drain cycle starts. "FLUSH" LED turns on and DV energizes. DV de-energizes after 20 minutes when drain cycle is initiated by 12-hr. DCT.
D. Bin Control Check 1) Remove the front and top panels. 2) Remove the storage bin cover. If necessary, dispense ice so that the BC actuator is not engaged or remove the ice manually. WARNING! Care should be taken to avoid the agitator during BC testing. 3) Move the control switch to the "OFF" position. 4) Move the power switch to the "OFF" position. 5) Turn off the power supply. 6) Disconnect red BC connector from the back of the control box.
E. Float Switch Check and Cleaning 1. Float Switch Check 1) Remove the front panel, then make sure the power switch is in the "ON" position. 2) Move the control switch to the "DRAIN" position. 3) Engage the safety switch and allow the evaporator and reservoir to drain. 4) Disengage the safety switch, then move the power switch to the "OFF" position and the control switch to the "OFF" position. 5) Turn off the power supply. 6) Disconnect F/S connector and check F/S continuity.
2. Float Switch Cleaning Depending on local water conditions, scale may build up on F/S. Scale on F/S can cause inconsistent operation of UF/S and LF/S. In this case, both UF/S and LF/S should be cleaned and checked. 1) Move the control switch to the "OFF" position. 2) Remove the front panel, then move the power switch to the "OFF" position. 3) Turn off the power supply. 4) Remove F/S assembly from the reservoir cover. See Fig. 1.
F. Diagnostic Charts Before consulting the diagnostic charts, check for correct installation, proper voltage per unit nameplate, and adequate water pressure (10 to 113 PSIG). Check CB using the steps in "IV.C. Control Board Check." 1. No Ice Production Startup 1. Power Supply a) Off, blown fuse, or tripped breaker. b) Not within specifications. 2. Water Supply a) Water supply off or improper water pressure. b) External water filters clogged. 3. Power Switch a) "OFF" position or defective. 4.
Ice Purge Cycle 1. Control Board a) No power to gear motor. 2. Gear Motor a) External protector (gear motor overload) open. b) Internal protector open. c) Motor winding open. d) Mechanical failure. 3. Coupling a) Defective. Freeze Cycle 1. Control Board a) Defective. 2. Compressor a) External protector open. b) Motor winding open. c) Capacitor defective. d) Start relay defective. e) Mechanical failure. 3. Fan Motor a) Motor winding or internal protector open. b) Bearing worn out or locked rotor.
2. Ice/Water Dispense Ice Dispense Push Button 1. Power Supply a) See "Startup." 2. Control Board a) Ice dispense switch circuit open or no power. b) No power to ice dispense solenoid, ice dispense motor, or agitating motor. 3. Ice Dispense Switch a) Defective. 4. Dispense Mode Switch a) Defective (open). 5. Ice Dispense Motor a) Open windings. 6. Ice Dispense Solenoid a) Defective or loose connection. 7. Shutter Assembly a) Mechanical failure. 8. Agitating Motor a) Open windings.
3. Opti-Serve (OS) Sensors Be sure to check all items in section "IV.F.2. Ice/Water Dispense" prior to using this chart. Use the following charts along with the wiring diagram to troubleshoot the OS sensors. Ice Sensor 1. OS Sensor a) Dirty. b) Defective. See chart 3a and 3b. 2. Control Board a) No power to infrared sensor. b) Not reading infrared sensor signal. Water Sensor 1. OS Sensor a) Dirty. b) Defective. See chart 3c. 2. Control Board a) No power to infrared sensor.
V. Removal and Replacement of Components WARNING • This icemaker 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 and turn off the power supply to the icemaker before servicing. Lockout/Tagout to prevent the power from being turned back on inadvertently.
1. Refrigerant Recovery This icemaker is provided with refrigerant access valves. Using proper refrigerant practices, recover the refrigerant from the service valves and store it in an approved container. Do not discharge the refrigerant into the atmosphere. 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.
4) Close the low-side valve and high-side valve on the gauge manifold. 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.
Evaporator Assembly Evaporator Assembly Spout A Spout B Cutter Extruding Head and Upper Bearing Power Switch Auger Control Switch Dispense Mode Switch Washer Allen Head Cap Screw Evaporator Allen Head Cap Screw with Washer Mechanical Seal Ring Housing and Lower Bearing O-Ring Hex Head Bolt with Washer Spline Coupling Fig.
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 front cover of the storage bin. Remove spout B, then remove spout A and the cutter. See Fig. 2. .
9) Move the power switch to the "ON" position, then replace the panels in their correct positions. 10) Turn on the power supply, then move the control switch to the "ICE" position to start the automatic icemaking process. 3. Removal and Replacement of Auger 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.
3) Remove the apron panel, then remove the left side panel. 4) Recover the refrigerant and store it in an approved container. 5) Remove the front cover of the storage bin. Remove spout B, then remove spout A. See Fig. 2. 6) Remove the allen head cap screws securing the extruding head. Using the cutter, lift out the auger assembly. 7) Remove the evaporator bracket and disconnect the water hoses. 8) Disconnect the inlet and outlet tubing.
5. Removal and Replacement of Mechanical Seal and Lower Housing 5a. Mechanical Seal 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.
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.
7. Dispense Auger and Agitator 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 front cover of the storage bin. 3) Remove the thumbscrews from the vertical plane, then loosen the thumbscrews from the horizontal plane of the motor bracket. Slide the motor back. Note: Hold the dispense auger/agitator to prevent it from dropping when sliding back the motor. See Fig. 4.
VI. Cleaning and Maintenance This icemaker must be cleaned and maintained in accordance with the instruction manual and labels provided with the icemaker. Consult with your local distributor about cleaning and maintenance service. To obtain the name and phone number of your local distributor, visit www.hoshizaki.com or call Hoshizaki Technical Support at 1‑800‑233‑1940 in the USA. WARNING • Only qualified service technicians should service this icemaker.
A. Cleaning and Sanitizing Instructions Hoshizaki recommends cleaning and sanitizing this icemaker at least twice a year. More frequent cleaning and sanitizing, however, may be required in some existing water conditions. WARNING • To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners. • Carefully follow any instructions provided with the bottles of cleaning and sanitizing solution.
9) In bad or severe water conditions, clean the float switch assembly as described below. Otherwise, continue to step 10. a. Remove the float switch assembly from the reservoir cover. b. Wipe down the float switch assembly with the cleaning solution. c. Rinse the float switch assembly thoroughly with clean water. d. Replace the float switch assembly in its correct position. 10) Move the power switch to the "ON" position and replace the panels in their correct positions.
9) Move the control switch to the "ICE" position. Open the icemaker water supply line shut‑off valve to supply water to the reservoir. 10) After the gear motor starts, move the control switch to the "DRAIN" position. Allow the water system to drain for 5 minutes. 11) Move the control switch to the "ICE" position. Allow the icemaker to run for 30 minutes, then clean and sanitize the dispense components as outlined below. 2.
8) Remove the spout cover, ice dispense spout, and water dispense nozzle. See Fig. 7. 9) Immerse the agitator, dispense auger, and parts removed in steps 5 through 8 in the cleaning solution and then in the sanitizing solution for 15 minutes each. Rinse the parts thoroughly with clean water. On Opti-Serve models (-OS), wipe the optical sensors with cleaning solution and then with a clean, damp cloth. 10) Wipe the shutter located above the ice dispense spout thoroughly with a clean cloth.
B. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the icemaker's environment, and local sanitation regulations. WARNING • Only qualified service technicians should service this icemaker. • Move the control switch and the power switch to the "OFF" position and turn off the power supply before servicing. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.
C. Preparing the Icemaker 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 icemaker is not used for two or three days under normal conditions, it is sufficient to only move the control switch to the "OFF" position. When storing the icemaker for extended time or in sub-freezing temperatures, follow the instructions below.
VII. Disposal This icemaker 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.
