Service Manual
Contents
1. WIRE COLOR CODE BK BL C BR BROW BU BLUE Js ou DBU DARK BLUE BK GR a WT 115 120 60 1 gt SoU LIGHT BLUE L GND Pi BR t R RED POWE M MEL des SWITCH Y YELLOW COMPRESSOR W W 2 H R WHITE BLACK CONTROL RELAY UP Me W R WHITE RED COMP START CAP RELAT Mos 3 4 145 1 74MF GY 99 29 1 W W O E a R 7 gle w T d GY 5 EXTERNAL DISPENSE RELAY PROTECTOR W BR W l 2 R R Bk gk GEAR MOTOR NTERNAL R s Tte PROTECTOR 5 6 BR Y 2 H BK 1 3718 w d EXTERNAL LIM PROTECTOR R 0 BK BR B R mi W W 08 BK BK R R R DBU l DBU ARAS W 4 N ax DRAIN VALVE 1 BK p BR LBU oTo W DBU FAN MOTOR BK R BK au ee o W DBU a BK W W 9 wo INLET WATER au VALVE R DEE A ge BR Fe W ox 0000 o CONTROL y W DBU mg TRANSFORMER oul FP Jur LBU LBU LB 24VAC LBU LBU BR DISPENSE WATER W R VALVE 0 LBU vg W DBU BK BK W O R R DBU DBU BK BK ec BR o BR BRA BR ICE gt WIR WRI WRI I WIR WIR BR BK 12 WARY 8 W DBU R2. Water Dispense Signal 8 P OVDC 5VDC Multimeter 5VDC Q Red Positive Red positive Test Lead N test lead to red Je Al Black Negative K4 connector 5 o 22 Test Lead pin closest to black K3 sE e e _ Control Board K7 Connector connector le O Water Dispense P Water Dispense W BK switch signal 5VDC power supply Fig 3 18 2 Opti Serve Model CB K8 connector pins 7 R 8 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 If the VDC matches the Engaged column below and the WTRDP LED does not turn on replace CB 5VDC CB K7 Connector Component Pin Wire Color CB VDC Ground Disengaged Engaged VDC Sensor Ground OVDC OVDC 7 R Water Dispense Signal 8 P To 5 Ka closest OVDC 5VDC 9 BK 5VDC Power Supply 9 BK 5VDC 5VDC Multimeter Red positive d Red Positive test lead to red Test Lead K4 connector 6 Black Negative 7 Tal vv Test Lead Control Board K7 Connector to black K3
3. m E 3 BK Dispense Motor 2 P Agitating Motor S 4 0 115VAC Input A N IIIMMININI 115VAC Input 3 BK LED Legend COMP compressor FLUSH DRAIN drain valve GM gear motor ICE dispense motor WTRDP water dispense valve WTRIN inlet water valve 5VDC Ground GND Terminals Fig 9a 30 S1 Dip Switch Open K9 Connector SERVICE Button Ice Purge Cycle Bypass K8 Connector Control Transformer 24VAC Input 1 W R Control Transformer 24VAC Neutral 2 LBU Bin Control 3 to 44 GY Float Switch Output M 5 BK 4 Upper Float Switch 6 R 7T T Lower Float Switch 7 BU K7 Connector Water Ice Dispense Output 2 Y _ T ice Dispense Input 3 W BK Water Dispense Input 8 P POWER OK LED K6 Connector 2 DCM 270BAH OS High Pressure Switch Compressor Relay 115VAC input BR 115VAC output R K1 Connector Input BR K2 Connector Drain Valve 10 W DBU Control Transformer Input 9 W R Compressor Delay Relay Circuit Relay De Energized Open 5VDC Relay Energized Closed OVDC K9 Connector SERVICE Button Ice Purge Cycle Bypass 3 to 4 Y Open
4. Ger connector m P 3 00 a als SH Water Dispense BK c o la lo ga 5VDC power Water Dispense P Water Dispense R switch signal VDC GND Fig 4 19 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 If the VDC matches the Engaged column below and the ICE LED does not turn on replace CB 5VDC CB K7 Connector Pin Wire Color CB VDC Ground Disengaged Engaged 5VDC Power Supply 3 W BK Red K4 pin closest 5VDC 5VDC Ice Dispense Signal 2 Y To to black K3 OVDC 5VDC Multimeter Red positive test lead to red to black K3 Test Lead connector 3LIH 11 11 Black Negative Test Lead VA 1 E 1 H A Y Control Board K7 Connector 1 5 H OI lol lo lo lo O dis E Ice Dispense Y ice dispense signal Ice Dispense W BK 5VDC power supply Fig 5 20 2 Opti Serve Model CB K8 connector pins 1
5. 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 The appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Young children should be properly supervised around the appliance Do not climb stand or hang on the appliance or appliance door or allow children or animals to do so Serious injury could occur or the appliance could be damaged Do not use combustible spray or place volatile or flammable substances near the appliance They might catch fire Keep the area around the appliance clean Dirt dust or insects in the appliance could cause harm to individuals or damage to the appliance NOTICE Follow the water supply drain connection and maintenance instructions 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 appliance 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 appliance on during extended periods of non use extended absences
6. If 115VAC is present on one and not the other replace CB If 115VAC is present on both check Comp windings start relay and capacitors Note If CDR de energizes CB K9 5 W O and CB K9 6 W O circuit opens Comp de energizes and an 8 beep alarm occurs See III B LED Lights and Alarm Safeties Diagnosis FM If FM does not energize check FM capacitor windings and bearings 7 Refill Cycle Low Water Safety As ice is produced the water level in the reservoir drops UFS opens Nothing occurs at this time When LFS opens WV energizes 90 sec low water safety timer fill timer starts Comp GM CDR and FM continue When UFS closes WV de energizes 90 sec low water safety timer fill timer terminates and 30 min freeze timer resets If UFS remains open 90 sec after WV energizes fill timer exceeded a 90 sec shutdown cycle starts Comp and FM de energize and CB signals a 1 beep alarm every 5 sec 90 sec ice purge timer starts GM and CDR continue to clear ice from the evaporator 90 sec purge timer terminates GM and CDR de energize WV and 1 beep alarm continue until UFS closes Diagnosis Check that WTRIN LED is on If not check LFS See II E Float Switch Check and Cleaning If LFS is open and WTRIN LED is off replace CB If WTRIN LED is on check that the reservoir fills If not check the water supply line restricted water filters WV solenoid restricted WV screen If WV is energized and refill exceeds 90 sec lo
7. DRA N jolce a 0 oo OFF 42 2345678910 23 W BK 7 E 2404 Lac R 1 DRAIN il HN x ONTROL LBU RELAYL_ WITCH 3 mw ai jM s FA HE WIBK gu CONTROL BOARD 2 Be d ge om Y He Wel Mode la r 5VDC 1 r SVDC E 5e W O g 9876 54 3 7 4 DCM 270BAH 0 Op 9 9 0 0 2 o 5 0 S o 2 Z o11 2 Ll60 W O p BK P R w Bx chung BU R K WIR yaa Torri LBU Du WATER GY BU a ee BIN DISPENSE W BK Sensor y B bi CONTROL BIO WIR 5 Dispenser D un EA SENSOR R E EE BU LOWER WATER ICE 2 S DISPENSE DISPENSE d SWITCH SWITCH F P NO E COM NO Y 5 7 1 DCM 270BAH W O W BK W BK EE W O w o 170 52
8. 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 Next check for 24VAC at CB K2 8 W BR to neutral LBU If 24VAC is not present replace CB If 24VAC is present turn off the power switch disconnect the WV wires and check WV solenoid continuity If open replace WV Reconnect WV wires move the power switch to the ON position then check that DV is not leaking by Check that WV shuts off when UFS closes Note Low Water Safety If UFS remains open 90 sec after WV energizes a 1 beep alarm sounds This alarm resets automatically once UFS closes 5 Ice Purge Cycle GM LED is on 5 sec GM delay timer and 30 min freeze timer start WV de energizes and WTRIN LED turns off Once the 5 sec GM delay timer terminates GM and CDR energize CDR cannot energize unless GM circuit is complete fuse internal protector and windings Once CDR energizes CB K9 5 W O and CB K9 6 W O 5VDC circuit closes and 5 min ice purge timer starts See II C 3 c Compressor Delay Relay 5 min Ice Purge Timer Circuit If CDR de energizes CB K9 5 W O and CB K9 6 W O circuit opens and an 8 beep alarm occurs See III B LED Lights and Alarm Safeties Note To bypass ice purge cycle and go straight to freeze cycle press SERVICE button on CB during 5 sec GM delay time Diagnosis CB Check that UFS closed WV LED turned
9. If not confirm CDR conacts are closed See step 2a 3 Compressor delay relay above If CDR contacts are closed replace CB If COMP LED turns on and Comp does not start check for 115VAC from the CB X1 relay BR and R to neutral W If 115VAC is present on CB X1 relay BR and not on CB X1 relay R replace CB Legend AM agitating motor gear motor this model BC bin control CB control board CDR compressor delay relay Comp compressor CT control transformer DV drain valve FM fan motor FT fill timer 90 sec low water safety GM gear motor PT purge timer LFS lower float switch UFS upper float switch WV inlet water valve K2 WV power Pin 48 O 22 D Bin Control Check When BC microswitch is not engaged BC circuit CB K8 3 GY and CB K8 4 GY is closed and the appliance produces ice S1 dip switch 7 must be in the OFF position and S1 dip switch 8 must be in the ON position When ice fills the bin and engages BC large balance plate BC opens and CB shutsdown the appliance within 10 seconds NOTICE Do not place S1 dip switch 7 in the ON position or S1 dip switch 8 in the OFF position For details see IILC 1 Default Dip Switch Settings 1 Move the power switch to the OFF position 2 Remove the front top and left side panels 3 Move the control switch to the OFF position 4 Remove the thumbscrews securing the storage bin cover WARNING Keep hands hair and loose clothi
10. Specification and Performance Data 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 amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 Ibs APPROXIMATE STORAGE CAPACITY REFRIGERANT CHARGE WEIGHT PERFORMANCE DATA APPROXIMATE ICE PRODUCTION PER 24 HR APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR gal day l day EVAPORATOR OUTLET TEMP oF C HEAD PRESSURE PSIG kg sq cmG SUCTION PRESSURE PSIG kg sq cmG TOTAL HEAT OF REJECTION 115 60 1 8 5 A AT 104 F 40 C WT 80 F 27 C N A N A 90 70 F 70 50 F 686 8 16 641 5 5 25 6 12 32 8 12 8 8 Ibs R 404A 14 8 oz 420g Net 152 Ibs 69 kg Shipping 170 Ibs 77 kg 50 282 128 259 118 248 113 228 103 219 99 201 91 192 87 172 78 1 654 6 3 gt Temp F 70 80 o R 1 680 694 34 128 1 118 30 173 7 103 26 99 4 91 23 87 1 78 20 7 23 3 23 4 4 4 3 2 2 2 2 2 2 20 7 5 23 5 4 24 4 2 4 217 15 2 217 15 2 251 17 6 251 17 6 285 20 0 285 20 0 285 X 327 23 0 327 23 0 327 23 0 37 2 6 37 2 6 37 2 6 40 2 8 40 2 8 40 2 8 43 3 0 43 3 0 43 3 0 46
11. and local codes and regulations The appliance requires an independent power supply of proper capacity See the nameplate for electrical specifications Failure to use an independent power supply of proper capacity can result in a tripped breaker blown fuse damage to existing wiring or component failure This could lead to heat generation or fire THE APPLIANCE MUST BE GROUNDED The appliance is equipped with a NEMA 5 15 three prong grounding plug 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 Failure to properly ground the appliance could result in death or serious injury Do not use an extension cord To reduce the risk of electric shock do not touch the control switch or plug with damp hands Make sure the control switch is in the OFF position before plugging in or unplugging the appliance Do not use an appliance 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 appliance be sure to pull the plug not the cord and do not jerk the cord A WARNING continued
12. or in sub freezing temperatures To properly prepare the appliance for these occasions follow the instructions in VI Preparing the Appliance for Periods of Non Use Do not place objects on top of the appliance The storage bin is for ice use only Do not store anything else in the storage bin L Construction and Water Refrigeration Circuit Diagrams A Construction oe ES DCM 270BAH T xL fj S D f i 4 a El p Ha CN Jr Wi te 44 UA B B 1 44 al v 0 51 ES HS LN EST un WU le a Mad 9 ju lt i 5 A 4 L 9 3 1 BBB D Je i i DCM 270BAH OS B Water Refrigeration Circuit Diagrams DCM 270BAH OS WEI Inlet Water Valve Water 0 e Supply Reservoir n JL Water Level 4 N Thermostatic Overflow Evaporator Expansion Valve Evaporator Water Supply Hose IS To Drain Gear Motor TOP e Dispense Water Valve Drier Fan High Pressure Switch Air Cooled Condenser Compressor Refrigeration Circuit ENENN Water Circuit lagnosis Il Sequence of Operation and Service D 19891 10 ZL Ul L 21 W pezifueue ep AG 21 ND pezi amp 1eue ep W4 JOYEM 19 UI AM Sejeuiule 10 urur or pazifisua AQ pezifueue ep dwo
13. 1 Default Dip A 33 2 Bin Control Shutdown Delay Infrared Sensor S1 dip switch 1 2 3 33 3 Drain Frequency Control S1 dip switch aaa 33 4 Continuous Dispensing Timer S1 dip switch 5 amp 6 34 5 Bin Control Selector 91 dip switch 7 b m s s 34 6 Bin Control Shutdown Delay 81 dip switch BI s eee iria 34 7 Factory Use S1 Dip Switch 9 amp Tinas 34 Re 35 IV Removal and Replacement of Components nennen 36 A Service Tor Felrigeranb LOS cc 36 1 Retrigerant F COV T e 37 37 3 Evacuation and Recharge 404 37 B Important Notes for Component 1 38 A M E 40 1 Upper Bearing Wear Check arica si 40 2 Removal and Replacement of Extruding Head aesti nna 41 3 Removal and Replacement of Auger 22aaaaaaaaaasssnnnnnnsnnnnnnnnnnnnnnnnnnnnnnannnni 41 4 Removal and Replacement of Evaporator 42 5 Removal and Replacement of Mechanical Seal and Lower Housing 43 6 Removal and Replacement of Gear 45 V EE 46 VI Preparing the Icemaker for Periods of 5 47 L 0 EE 48 VIII Technical TOMA GW RR 49 A Specifi
14. 32 46 32 46 32 217 152 251 17 6 N Oe 3532 BTU h AT 90 F WT 70 F 49 2 DCM 270BAH OS SPECIFICATION SHEET AC SUPPLY VOLTAGE 115 6071 AMPERAGE 8 5 A AT 104 F 40 C WT 80 F 27 C MAXIMUM FUSE SIZE N A MINIMUM CIRCUIT AMPACITY N A ELECTRIC amp WATER CONSUMPTION 90 70 F 70 50 F ELECTRIC W kWH 100 lbs 669 8 16 638 5 3 WATER gal 24HR gal 100 Ibs 26 12 35 12 APPROXIMATE STORAGE CAPACITY 8 8 Ibs REFRIGERANT CHARGE R 404A 14 8 oz 420 g WEIGHT Net 152 Ibs 69 kg Shipping 170 Ibs 77kg PERFORMANCE DATA APPROXIMATE ICE Ambient PRODUCTION PER 24 HR Temp E 50 Ibs day kg day 197 89 189 86 176 80 APPROXIMATE ELECTRIC CONSUMPTION 6 2 Od Gd c l GO Ol ool O watts APPROXIMATE WATER d 0 CONSUMPTION PER 24 HR 0 0 TOTAL 0 0 gal day day 0 0 EVAPORATOR OUTLET TEMP 21 6 22 F C N alan Bele 25 4 28 28 2 28 2 28 2 HEAD PRESSURE 219 154 325 22 8 219 15 4 325 22 8 219 15 4 325 22 8 PSIG kg cm G 219 154 284 19 9 325 22 8 SUCTION PRESSURE 37 26 46 3 2 PSIG kg cm G 37 46 37 2 6 46 32 37 2 6 42 3 0 1 46 32 TOTAL HEAT OF REJECTION 3532 BTU h AT 90 F WT 70 F B Fo 0 CH 0 CH 0 25 lt e N lt N o IC
15. 5VDC Closed OVDC 5 to 6 W O Control Switch 1 to 2 W BK ICE Open 5VDC DRAIN Closed OVDC ER 5vpc IVASLL NIVHG Inlet Water Valve z 8 O Ka Control Transformer Input 7 W R 1 I NIIIM ANIT dst TLM Dispense Water TTO Valve 6 W O 24VAC Input s lt 5 W R Gear Motor ice dispense 4 BK pv T UOT T IT MMT ovino 115VAC Input 3 BR Ice Dispense Solenoid 2 DBU 115VAC Input 1 BK MTT LED Legend COMP compressor FLUSH Drain drain valve GM gear motor ICE dispense motor WTRDP water dispense valve WTRIN inlet water valve Open 5VDC Ground GND Terminals Fig 9b 31 K6 Connector K8 Connector 24VAC and 5VDC Control Transformer 24VAC Input 1 W R Control Transformer 24VAC Neutral 2 LBU Bin Control 3 to 4 GY Open 5VDC Closed OVDC Float Switch Output 5 BK Upper Float Switch 6 R Open 5VDC to 5 black Closed OVDC to 5 black Lower Float Switch 7 BU Open 5VDC to 5
16. 5VDC or not reading circuit b Compressor relay defective 2 Start Relay 3 Start Capacitor 4 Compressor TT e 5 High Pressure Switch Activates 6 Fan Motor a Capacitor defective b Motor winding c Bearing worn out or locked rotor 7 Evaporator b Damaged or defective 8 Thermostatic Expansion Valve 10 Drain Valve Ref a Off 2 Control Board a No power to float switch 5VDC or not reading float switch condition 3 Float Switch T Bin Contra 27 2 Ice Water Dispensing Ice Dispense Push Button 1 Power Supply a Off blown fuse or tripped breaker 2 Control Board a No power from control board to ice dispense switch BVDC or not reading signal 2 Control Board a No power from control board to OS sensor 5VDC or not reading signal T Power Supply 2 Control Board a No power from control board to water dispense switch 5VDC or not reading signal 3 Water Dispense Switch 4 Water Dispense Valve 2 Control Board a No power from control board to OS sensor 5VDC or not reading signal 4 Water Dispense Valve 28 lll Controls and Adjustments A Hoshizaki exclusive control board is employed in Hoshizaki icemakers All models are pre tested and factory adjusted e 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
17. If 5VDC is not present on either pin replace CB If 5VDC is present on pin 3 GY and not on pin 4 GY BC is open See ID Bin Control Check b Float Switch FS Upper UFS and Lower LFS CB K8 connector pins 5 common BK 6 UFS R and 7 LFS BU 5VDC is present between CB K8 connector pin 5 common BK and CB red K4 connector pin closest to CB black K3 connector at all times If 5VDC is not present replace CB For further float switch diagnostics see II E Float Switch Check and Cleaning 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 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 If not confirm that the water dispense signal VDC matches the Engaged column in the table below If not check the water dispense switch continuity when engaged closed If the water dispense switch is open when engaged replace the water dispense switch If the VDC matches the Engaged column below and the WTRDP LED does not turn on replace CB 5VDC CB K7 Connector Pin Wire Color CB VDC Ground Disengaged Engaged 5VDC Power Supply 3 W BK Red K4 pin closest 5VDC 5VDC To to black K3
18. Service for Refrigerant Lines A WARNING Repairs requiring the refrigeration circuit to be opened must be performed by properly trained and EPA certified service personnel Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere 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 NOTICE Do not leave the system open for longer than 15 minutes when replacing or servicing parts 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 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 36 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
19. 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 If the VDC matches the Engaged column below and the ICE LED does not turn on replace CB 5VDC CB K7 Connector Pin Wire Color CB VDC Ground Disengaged Engaged OVDC OVDC Ice Dispense Signal 2 Y To Red K4 pin closest oypc 5VDC to black K3 5VDC Power Supply 3 W BK 5VDC 5VDC omponent VDC Sensor Ground 1 W R Multimeter Red positive Ly Red Positive test lead to red 5 Test Lead K4 connector pin closest to black K3 To connector DN Black Negative A 15 gt Test Lead H U U s 1 1 rv x LAD X 1 U 1 1 d x Control Board K7 Connector 8 996869 5t LA Ice Dispense VV R VDC ground Ice Dispense Y Ice Dispense W BK ce dispense signal 5VDC power supply Fig 6 21 3 Fill Cycle VVTRIN 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
20. be replaced Instructions for removing the extruding head and housing 2 are located later in this procedure a ace Note Replacing the bearing requires a Fig 3 bearing press adaptor If one is not available replace the whole extruding head and housing 4 Replace the drip pan agitator and top of the storage bin in their correct positions 5 Move the power switch to the ON position then replace the panels in their correct positions 6 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 40 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 Remove the apron panel then remove the left side panel 5 Remove the allen head cap screws and lift off the extruding head 6 Place the new extruding head in place and tighten down the allen head cap screws 7 Replace the cutter in its correct position 8 Replace spout A spout B and the front cover of the storage bin in their correct positions 9 Move the pow
21. production remove the front top and left side panels Place a container under the spout and dispense all ice from the icemaker Note The ice dispense switch times out after 20 sec Re engage every 20 sec until bin is empty Move the control switch and power switch to the OFF position Remove the bin top cover Pour warm water over the remaining ice After the ice is removed melted place the bin top cover in its original position Do not secure at this time Remove the control box cover then move the control switch to the ICE position and the power switch to the ON position Once the gear motor starts press the SERVICE button on the control board located in the control box WARNING Risk of electric shock Care should be taken not to touch live terminals Lift the bin top cover and monitor the evaporator extruding head WARNING Keep hands hair and loose clothing clear of the agitator rotating inside of the storage bin Once ice begins to fill the bin start a 10 min timer After 10 min move the power switch to the OFF position Place an empty container under the spout and dispense all ice from the icemaker Note The ice dispense switch times out after 20 sec Re engage every 20 sec until bin is empty Move the power switch to the OFF position Weigh the ice to establish the batch weight minus the weight of the container Multiply the batch weight by 144 for the total production in 24 hr Replace the control box cover and bin to
22. 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 Do not touch the electronic devices on the control board or the back of the control board Do not change wiring and connections Do not misconnect terminals Do not short out power supply to test for voltage Always replace the whole control board assembly if it goes bad 29 A Control Board Layout 1 DCM 270BAH Control Switch 1 to 2 W BK ICE Open 5VDC DRAIN Closed 0VDC High Pressure Svvitch 3 to 4 Y Open 5VDC Closed OVDC Compressor Delay Relay Circuit 5 to 6 W O Relay De Energized Open 5VDC Relay Energized Closed OVDC PA Compressor Relay 115VAC input BR 115VAC output R IN K1 Connector 3 GM DBU 2 GM Voltage Input BR OVASLL K2 Connector Drain Valve 10 W DBU Control Transformer NIVHG Input 49 W R see Inlet Water Valve c 8 W BR li Control Transformer L I 1 1111 ANIL dst Input 7 W R Dispense Water Valve 6 W O 5 24VAC Input a TOTEM 5 W R AL T wett ova gt
23. the DRAIN position Allow the water system to drain for 5 minutes 3 Dispense all of the ice from the storage bin 4 Attach a compressed air or carbon dioxide supply to the icemaker water supply line drain valve 5 While engaging the water dispense switch blow out the water dispense valve using the compressed air or carbon dioxide supply After blowing out the water dispense valve leave the compressed air or carbon dioxide supply flowing Move the control switch to the ICE position to open the inlet water valve and briefly blow out the inlet water valve After blowing out the inlet water valve move the control switch to the OFF position 6 Close the icemaker water supply line drain valve 7 Move the power switch to the OFF position then unplug the icemaker from the electrical outlet 8 Remove the storage bin cover Clean the storage bin liner and the storage bin cover using a neutral cleaner Rinse thoroughly after cleaning Replace the storage bin cover front panel air filter and louver in their correct positions Control Switch Power Switch 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 48 VIII Technical Information We reserve the right to make changes in specifications and design without prior notice A
24. 7 Move the power switch to the ON position to start the automatic icemaking process Legend BC bin control CB control board Comp compressor GM gear motor 23 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 After cleaning check them again Replace if necessary 3 Replace the FS molex plug on the control box 4 Move the control switch to the ICE position 5 The reservoir fills Once UFS closes GM starts 6 Move the control switch to the OFF position 7 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 With the reservoir full float switches are closed If open follow the steps in II E 2 Float Switch Cleaning After cleaning check them again Replace if necessary 8 Move the control switch to the ICE position 9 Replace the left side top and front panels in their correct positions 2 Float Switch Cleaning Depending on water conditions scale may build up on FS Sc
25. A G wnuwixeyy wd Ol U pe 7 Sues y SHES Ld 998 06 2 bip A uone1edo joaye ou seoq 2 lt 2 ap eBing eo z Spunos uueje d q Y M9H ki L seus diq ps SEIS ND dnes L pue wieje a 14 09S 06 4nou spuooes z 10 seziDieue AG 9049 ureJp 16001 s solo SAN UUM 4 Ayayes 19 8AA MOT 2 l 4 eBung 4 111 E SS y 1 pesay Y 3249 uq 21 1 E ees eouenbes ajo o ZL Ul JOY ejqejre e si UreJp ZL UI L e pepueululooei si 9199 up Ul ynejap 15 v uBnouyy ejoA2 10 Z ur M SO H 8022 W2a eys MOL eouenbes PILOG 104002 V J A Sequence of Operation Flow Chart B Service Diagnosis A 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 Make sure that none have fallen into the storage bin Make sure all food zones in the appliance are clean after service For cleaning procedures see the instruction manual or the maintenance label 1 Ice Production Check To check ice
26. BK If not confirm 5VDC between pin 1 W BK and CB red K4 connector pin closest to CB black K3 connector If 5VDC is not present replace CB DRAIN Position When control switch is in the DRAIN position CB K9 connector pin 1 W BK and pin 2 W BK are closed 5VDC is present between both CB K9 connector pin 1 W BK and pin 2 W BK to CB red K4 connector pin closest to CB black K3 connector If 5VDC is not present replace CB b High Pressure Switch HPS CB K9 connector pins 3 Y and 4 Y When HPS is closed 5VDC is present between both CB K9 connector pins 3 Y and pin 4 Y to CB red K4 connector pin closest to CB black K3 connector If 5VDC is not present on pin 3 Y or pin 4 Y replace CB If 5VDC is present on CB K9 connector pin 3 Y and not on CB K9 connector pin 4 Y HPS is most likely open CB sounds a 3 beep alarm Check HPS continuity If HPS is open and CB is not in alarm replace CB c Compressor Delay Relay CDR CB K9 connector pins 5 W O and 6 W O When CDR is de energized GM off CDR terminals 3 and 5 are open and 5VDC is present between CB K9 connector pin 5 W O and CB K9 connector pin 6 W O If 5VDC is not present check CDR continuity between terminals 3 and 5 If open replace CB When CDR is energized CDR terminals 3 and 5 close and OVDC is present between CB K9 connector pin 5 W O and pin 6 W O 5VDC is present between CB K9 connector pin 5 W O to CB red K4
27. Freeze Timer Manual reset Turn power off and on again WV off gt 30 minutes since last WV activation Low Voltage POWER OK LED turns off if voltage 92Vac 5 or less protection operates 7 High Voltage The control voltage safeties automatically 147Vac 5 or more reset when voltage is corrected 4 High Pressure Switch Call for service To avoid possible catastrophic Third activation in 1 hour failure it is recommended to leave the appliance off until this alarm is resolved Manual reset Turn power off and on again 8 GearMotor Manualreset Turn power off and on again Bin Control Infrared Sensor Manual reset Turn power off and on again 81 dip switch 7 Not used on this model Legend Comp compressor DispWV dispense water valve DV drain valve FM fan motor GM gear motor IDSV ice dispense solenoid valve UFS upper float switch WV inlet water valve 32 C Settings and Adjustments 1 Default Dip Switch Settings The S1 dip switch settings are factory set to the following positions DipSwichNo 1 2 3 4 5 6 7 8 9 10 Normally off factory use Bin Control Shutdown Delay mechanical and Periodic Agitation of Storage Bin Bin Control Selector Continuous Dispensing Timer Do not adjust on DCM 270BAH OS Drain Frequency Control Bin Control Shutdown Delay infrared sensor 2 Bin Control Shutdown Delay Infrared Sensor S1 dip switch 1 2 3 NOTICE Do n
28. Hoshizaki America Inc Cubelet cemaker Dispenser Models DCM 270BAH OS F A Control Board Models SERVICE MANUAL A Superior Degree of Reliability www hoshizaki com Number 73202 Issued 5 6 2014 Revised 7 2 2014 A 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 Proper installation is the responsibility of the installer Product failure or property damage due to improper installation is not covered under warranty Hoshizaki provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should the reader have any questions or concerns which have not been satisfactorily addressed please call send an e mail message or write to the Hoshizaki Technical Support Department for assistance Phone 1 800 233 1940 770 487 2331 Fax 1 800 843 1056 770 487 3360 E mail techsupport 9 hoshizaki com HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn Hoshizaki Technical Support D
29. LED turns on Diagnosis POWER OK LED Check that CB POWER OK LED is on If not check for 115VAC at control transformer brown BR wire to neutral W If 115VAC is not present check the power switch power cord connection and breaker If 115 VAC is present check control transformer continuity Replace as needed Next check for 24VAC at control transformer red R wire to neutral LBU If 24VAC is not present check control transformer continuity Replace as needed If 24VAC is present check 24VAC 1A fuse If fuse is good check for 24VAC at CB K8 1 W R to CB K8 2 LBU If 24VAC is present and POWER OK LED is off replace CB Diagnosis DV If DV does not energize check for 24VAC at CB K2 10 W DBU to neutral LBU If 24VAC is not present check control switch continuity If open while in the DRAIN position replace control switch If closed check for OVDC at control board K9 1 W BK to K9 2 W BK If 5VDC is present and control switch is closed replace CB If 24VAC is present check for restricted DV and DV solenoid continuity Clean or replace as needed 3 After all of the water has drained move control switch to the ICE position 11 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
30. MOTOR w m BK R GND BK Fro W DBU Bk w s Lau INLET WATER eu VALVE 120VAC 4 BR BR BR w W W O CONTROL Bl 0 woBu M Ce ono TRANSFORMER BK R FUSE 1A 24VAC LBU usu LBU LBU LBU BR DISPENSE WATER WR wDBU VALVE 6 WIO BK BK R R DBU BK 0 WDBU 1 BR e BR BR BR ICE WIR WR wr WIR WIR Ze m WIO wo BR sr wpsu BR BK R DRAIN 1 CCE n 9 600000000 o oo N OFF J2 23456182910 23 VV BK 2 mA Ensvac Eau 5VAC J 7 R DRAIN Ke oli x CONTROL H SWITCH Be 51 FA VV BK ES CONTROL BOARD Zort m 3e HI PRESS KI K8 c Y 1 s K5 SWITCH OW ar cat PIN wo A 98765432 I 8765432 s lL E T wo DCM 270BAH OS 6 99900000 9 0999990090 o gt P e BK G wiBK Y V R Bu R BK we Wi L esTl TT LBU LBU WATER Y BU W DISPENSE IN GY BIN SENSOR R WIBK BK CONTROL R UPPER BK les W WIR N D SPENSE BU SENSOR 5 BU LOWER WATER ice FLOAT SWITCH SWITCH SWITCH P NO COM NO w o o o o we vek wed NDCN 270BAH Wo wid Wo 51 2 DCM 270BAH OS a Serial Number C17634M C17641M and D00833A and Later
31. ainer Clip A I Float Switch Assembly X Reservoir Cover z Fig 8 25 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 1 Power Supply a Off blown fuse or tripped breaker 2 Power Swich 3 Control Transformer 4 1A 24VAC Fuse Contro Box 5 Control Switch a In DRAIN position b Bad contacts 6 Control Board a In alarm See 11 LED Lights and Audible Alarm Safeties See ILC Control Board Check b Defective 7 Bin Control a Tripped with bin filled with ice b Microswitch defective C Large balance plate does not move freely 8 High Pressure Switch a Control board in 3 or 4 beep alarm See 11 LED Lights and Audible Alarm Safeties Fill Cycle 1 Control Board a No power to inlet water valve 24VAC b No power to float switch 5VDC or not reading float switch condition 2 Inlet Water Valve 8 Screen or orifice clogged b Coil winding Vv 4 Float Switch 5 Drain Valve a Sticking 2 Gear Motor 3 Water Supply a Water supply off or improper water pressure 26 No Ice Production Possible Cause Freeze Cycle 1 Control Board a No power to compressor delay relay circuit
32. ale on the switch can cause the floats to stick In this case FS should be cleaned and checked 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 move the control switch to the OFF position and the power switch to the OFF position 3 Remove FS assembly from the reservoir cover See Fig 8 4 Wipe down FS assembly with a mixture of 1 part Hoshizaki Scale Away and 25 parts warm water Rinse the FS assembly thoroughly with clean water 5 While not necessary the floats can be removed from the shaft during cleaning If you remove them note that the blue float is on top The floats must be installed with the magnets inside them towards the top of the switch See Fig 8 Installing the floats upside down will affect the timing of FS operation 6 Rinse FS assembly thoroughly with clean water and replace in its correct position 7 Move the control switch to the ICE position 7 Replace the left side top and front panels in their correct positions 8 Move the power switch to the ON position to start the automatic icemaking process Legend Comp compressor FS float switch GM gear motor 24 Red B 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 Ret
33. an approved container Do not discharge the refrigerant into the atmosphere 2 Brazing A 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 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 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 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 ga
34. 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 If the WTRIN LED is on and 24VAC is not present between CB K2 connector pin 8 O and neutral LBU confirm 24VAC at CB K2 connector between pin 7 W R and neutral LBU If 2AVAC is present between CB K2 connector pin 7 W R and neutral LBU and not between CB K2 connector pin 8 O and neutral LBU replace CB 24VAC CB K2 Connector LFS LFS Connector Pin Wire Color To Neutral LBU Open Closed K2 CB input power Pin 47 W R K8 pin 2 LBU OVAC 24VAC 4 Ice Purge Cycle GM LED is on GM LED turns on once UFS closes reservoir full If UFS is closed and GM LED is off replace CB If GM LED is on but GM does not start check for 115VAC from CB K1 connector pin 3 BK to neutral W If 115VAC is not present confirm 115VAC from CB K1 connector pin 2 BR to neutral W If 115VAC is present on CB K1 connector pin 2 BR but not on CB K1 connector pin 43 BK replace CB Once GM energizes CDR energizes and 5 min PT starts 5 Freeze Cycle GM and COMP LED are on 5 min PT terminates or press the SERVICE button on CB after the GM LED turns on to bypass ice purge cycle WARNING Risk of electric shock Care should be taken not to touch live terminals After 5 min PT terminates COMP LED turns on
35. anical seal consists of two parts One moves along with the auger and the other is fixed on the lower housing NOTICE If the contact surfaces of these two parts are worn cracked or scratched the mechanical seal may cause water leaks and should be replaced Instructions for removing the mechanical seal and lower housing are located later in this procedure 12 Make sure the lower mechanical seal is in place then place the new evaporator in position Secure the evaporator to the lower housing using the allen head cap screws 13 Remove the drier then place the new drier in position 14 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 42 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 17 Install the auger assembly with the upper part of the mechanical seal attached and tighten down the allen head cap screws 18 Replace the evaporator bracket and reconnect the water hoses 19 Replace spout A spout B and the front cover of the storage bin in their correct positions 20 Move the power switch to the ON position then replace the panels in their corre
36. black Closed OVDC to 5 black K7 Connector OS Ice Sensor 1 W R Ice Dispense 2 Y Ice Dispense Output 3 W BK Water Dispense Signal 8 P OS Water Sensor Output 49 BK 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 Il Sequence of Operation and Service Diagnosis Icemaking Sequence wee m o mem Xu mom oo l Alarm sounds after 90 sec lce Purge Cycle GM Joy Jam mm Freeze Cycle GM WTRIN refill On until UFS closes with refill COMP Alarm sounds after 90 sec Drain Cycle FLUSH Drain Io 2se 10min Dispensing Sequence Sequence Step LED Kl Time LEDs are on CE Ice Dispense l GM IDSV Factory set for IDSV de energizes on internal Activation overload after 3 to 4 min Resets when cool Dispense Water WTRDP DispWV Valve Activation The built in alarm safeties shut down the appliance No of Beeps 1 Low Water Safety Automatic reset once water supply is restored UFS open gt 90 seconds after WV energized and UFS closes Control Switch Automatic reset once the control switch is In DRAIN position longer than 15 minutes moved to the ICE position 3 High Pressure Switch Automatic reset once pressure drops First and second activation in 1 hour below the high pressure threshold and the high pressure switch closes 5
37. cation and Performance 0 49 1 DCM 270BA F A en a A 49 2 DCM 270BAH OS E 50 pa cel EE 51 1 DCM 270BAH OS E 51 2 DCM 270BAH OS E 52 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 A 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 A WARNING The appliance 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 injury or damage resulting from improper incorrect and unreasonable use 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 To reduce the risk of death electric shock serious injury or fire follow basic precautions including the following Only qualified service technicians should install and service the appliance The appliance must be installed in accordance with applicable national state
38. connector pin closest to CB black K3 connector and CB K9 connector pin 46 W O to CB red K4 connector pin closest to CB black K3 connector If GM is energized and CDR terminals 3 amp 5 are open an 8 beep alarm occurs See III B LED Lights and Audible Alarm Safeties If CDR terminals 3 and 5 are closed and OVDC is present between CB K9 connector pin 5 W O and pin 6 W O 5 min Comp delay timer starts If Comp does not energize after 5 min delay timer terminates replace CB 2b 5VDC CB K8 Connector See Fig 2 5VDC CB K8 Connector Pin Wire Color Bin Control BC 3 GY and 4 GY Float Switch FS Common 5 BK Common Upper Float Switch UFS 6 R Lower Float Switch LFS 7 BU Multimeter Red positive Y test lead to red K4 connector pin closest og to black K3 Red Positive connector zl Test Lead d DA Ly p Black Negative El y Test Lead 5 i Control Board K8 Connector Ol Ol lo o 112 Bin Control GY Float Switch FS Common BK Upper Float Switch UFS R Lower Float Switch LFS BU Fig 2 2b 5VDC CB K8 Connector Continued a Bin Control BC CB K8 connector pins 3 GY and 4 GY When BC is closed icemaking 5VDC is present between CB K8 connector pin 3 GY and pin 4 GY to CB red K4 connector pin closest to CB black K3 connector
39. ct positions 21 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 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 4 Remove the apron panel then remove the left side panel 5 Remove the extruding head heater and the allen head cap screws securing the extruding head 6 Using the cutter lift out the auger assembly then remove the evaporator bracket 7 The mechanical seal consists of two parts One moves along with the auger and the other is fixed on the lower housing NOTICE If the contact surfaces of these two parts are worn cracked or scratched the mechanical seal may cause water leaks and should be replaced 8 Remove the allen head cap screws securing the evaporator to the lower housing 9 Raise the evaporator up to access the lower housing 10 Remove the mechanical seal from the housing If only replacing the mechanical seal proceed to step 13 NOTICE To help prevent water leaks be careful not to damage the surfaces
40. d Drain Valve the inlet water valve screen and clean and inspect the drain valve Inspect the water hoses and clean replace if necessary Condenser Inspect Clean if necessary by using a brush or vacuum cleaner Appliance Inspect for oil spots loose components fasteners and wires Upper Bearing Check for wear using 02 round stock or pin gauge Replace both upper extruding head bearing and lower bearing if wear exceeds factory recommendations See IV C 1 Upper Bearing Wear Check After Upper Bearing Inspect Replace both upper bearing and lower bearing if wear exceeds 3 Years extruding head factory recommendations Replace the mechanical seal if the seal s contact then Yearly Lower Bearing surfaces are worn cracked or scratched and O Ring lower housing Mechanical Seal Evaporator Cylinder Auger 46 VI 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 power switch to the OFF position When storing the icemaker for extended time or in sub freezing temperatures follow the instructions below 1 Close the icemaker water supply line shut off valve and open the icemaker water supply line drain valve 2 Remove the louver and air filter then move the control switch to
41. e 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 5 Remove the evaporator bracket 6 Remove the bolts securing the lower housing to the gear motor Lift the evaporator up slightly 7 Remove the 3 gear motor bolts 8 Disconnect the wiring from the gear motor then remove the gear motor 9 Remove the spline coupling from the old gear motor and attach to the new gear motor 10 Place the new gear motor in the drain pan 11 Secure the gear motor 12 Connect the gear motor wires 13 14 15 Replace spout A spout B and the front cover of the storage bin in their correct positions Lower the evaporator down and secure it to the gear motor Replace the evaporator bracket in its correct position 16 Move the power switch to the ON position then replace the panels in their correct positions 17 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 45 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 A WARNING Only qualified service technicians should service the appliance Move the control s
42. epartment Web Site www hoshizaki com NOTE To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem 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 Satety ed ee EE 5 Construction and Water Refrigeration Circuit Diagrams 7 E EE 7 B Water Refrigeration Circuit Diagrams aaaaaaaaanaaaaaaaaananaannnnnnnnnnnnnnnnsnnnnnnnnnnnnnnnnnuna 8 Il Sequence of Operation and Service Diagnosis 4 4 9 A Sequence of Operation Flow EM GE 9 Service DINOS suscita 10 Control Board Bia a a a oE a 14 D BiM Control e e unica 23 Es Float Switch Check and CS An NG sesmaria aieiaa 24 F Diagnostic Table C ncc PI 26 I Controls and diuimeni b ar a aet npn aan banana sp nd Rae 29 A Control Board Layout esnias nne a a e ASEE EN 30 B LED Lights and Audible Alarm Safeties 32 Es TRE e Susi 33
43. er 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 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 5 Remove the allen head cap screws securing the extruding head Using the cutter lift out the auger assembly 6 Remove the cutter extruding head and upper part of the mechanical seal from the auger and place them on the new auger NOTICE To help prevent water leaks be careful not to damage the surfaces of the O ring or mechanical seal 7 Install the new auger assembly with the upper part of the mechanical seal attached and tighten down the allen head cap screws 8 Replace spout A spout B and the front cover of the storage bin in their correct positions 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 s
44. g y9yms 180 19ddn S4N yoyms erer p youms dip Ls AOQE 3 9 141 O lt JOJOU 1888 44 s jeuondo 11e159y 9 Kajes 1818 MO JEW 1 13 118 59y s ypul i ueia lnulin 01 ejo 9 eBung 291 z oq sentur 1a L 4 uleig cL Ur L lt lt M MR EE NPA UI5 P AQ peBeBuesip aouejeq abe 28 194 ureip La E ua pasoj9 3g Pazifiaua sp sjuauoduloo IV JosseJdujoo duio3 AOQE 2 efung 971 z 001 ana Q S OL 019 HEYS M HO yewa Z INJ L sueis l eBung Z pue sjeseJ uue e 5950 9 SAN ueuM ajejd s9uejeq 961 28 uedo 28 gt umopinus 21 W peziBJeue WE 21 M pezi amp ieue AM pezi amp 1eue ep W4 peziBieue W4 2 WA spunos uueje desq peziBieue ep duo 2 dwog peziBjeue duo y 14988 06 lt Ill JI 21 AM paziB1aua 2p AM 21 AM peziBieua ep AM 2 WEI uedo s n sajeulula 14 S 06 5818 14 6 pezifueue AM SES 14 p soro s n uedo S41 ab org w 7 98s 14 s nunuoo uueje deaq spunos uueje dasq 1 peso S41 uedo SAN p zi5s u due 2 W9 pesoi S41 paz AM Pa S lbulu 9 q D x 14 WE EE EE spuooes 06 uo 31 40 H3MOd Spuoo es 06 Sspuooes 06
45. i 50 B Wiring Diagrams 1 DCM 270BAH OS a Serial Number C10508L to D00829A except C17634M and C17641M WIRE COLOR CODE BK BLACK BR BROWN BU BLUE Be 4 DBU DARK BLUE BR W GR GR GREEN GY GRAY 115 60 1 gt LIGHT BLUE N O ORANGE l GND P PINK BR W R RED 2 V VIOLET 2 AER w WHITE 3 Y YELLOW WIBK WHITE BLACK COE EY x VV BR WHITE BROWN VV BU WHITE BLUE 1 2 WO WHITE ORANGE START WIR WHITE RED START CAP RELAY wo 3 4 145 7AMFD Y 29 29 0 5 6 W WO bd pese BK 7 8 29 W A GY 5 2 DISPENSE RELAY W w 1 2 w R R BR BK sera 3 4 BK BK GEAR MOTOR INTERNAL g 9o Y PROTECTOR 2 es cap YE 7 318 jw 10MFDW EXTERNAL 3 PROTECTOR DBU BK BR BR BK W W W BK BK DBU BK DBU l DBU GY ANS uM RIA DISPENSE GND SOLENOID LBU DRAIN VALVE h BK BR LBU WIDBU FAN
46. ing IC e AVI i Gei A wu is ___ 0 Ring Evaporator Assembly MEM Extruding Head Upper Bearing Auger Lab rd ead ad i UP Cover Seal Bolt Evaporator GC Co Socket Head Cap Screw Mechanical Seal F ng Housing Lovver Bearing Gear Motor __ Spline Coupling Fig 8 39 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 Agitator 3 Grasp the top of the auger and move the auger towards you then try to insert a 02 round stock or pin gauge in between Drip Ring the back side of the auger shaft and the bearing surface Check several locations 02 Round Stock around the auger shaft If the gauge goes or Pin Gauge between the shaft and the bearing at any point or if the bearing is scratched or cracked both the top bearing in the extruding head and the lower bearing in the housing should
47. ip switch settings to assure that they are in the factory default position For factory default settings see 11 1 Default Dip Switch Settings S1 dip switch 7 determines bin control application WARNING Do not adjust S1 dip switch 7 out of the factory default position This dip switch must be left in the factory default position or the appliance will not operate correctly e When checking for 115VAC high voltage primary always choose a 115VAC neutral W to establish a good neutral connection e When checking for 24VAC low voltage secondary always choose a 24VAC neutral LBU to establish a good neutral connection If the appliance is in alarm see 111 B LED Lights and Audible Alarm Safeties e When checking for 5VDC use CB red K4 connector pin closest to CB black K3 connector for DC ground GND 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 NOTICE Appliance will not start unless the safety switch is engaged 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 If 24VAC is present and POWER OK LED is off replace CB 2 5VDC Output Chec
48. itch 7 in the off position the gear motor delay after the upper float switch closes is 5 seconds WARNING Do not adjust S1 dip switch 7 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 Application Gear Motor Delay Bin Control Mechanical Bin Control Infrared Sensor with Mechanical Bin Control Backup 6 Bin Control Shutdown Delay and Storage Bin Agitation Timer S1 dip switch 8 Factory set for normal operation No adjustment is required The shutdown delay is the time between the bin control microswitch opening and the control board shutting off the appliance A 2 second periodic agitation occurs every 90 minutes S1 Dip Switch Salir Bin Control 1 Storage Bin Mon Shutdown Delay Periodic Agitation 0 25 Seconds 6 7 Seconds 7 Factory Use S1 Dip Switch 9 amp 10 Factory set for optimum performance Do not adjust 34 D Switches The power switch and control switch are used to control the operation of this icemaker 1 Power Switch The power switch has 2 positions OFF and ON 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 closes a 5VDC circuit from control board K4 connector pin 3 W R to control board K4 connector pin 44 W R Whe
49. ks There are seven 5VDC circuits on the appliance 8 3 circuits at CB K9 connector Control switch DRAIN position high pressure switch HPS and compressor delay relay CDR b 2 circuits at CB K8 connector Bin control BC and float switch FS upper and lower C 2 circuits at CB K7 connector Ice dispense push button and OS sensor and water dispense push button and OS sensor 2a 5VDC CB K9 Connector See Fig 1 5VDC CB K9 Connector Pin Wire Color Control Switch DRAIN Position 1 W BK and 2 W BK High Pressure Switch HPS 3 Y and 4 Y Compressor Delay Relay CDR 5 W O and 6 W O CDR relay terminals 3 W O and 5 W O Red positive test lead to red K4 connector pin closest to black K3 connector Ter Multimeter 1 DRAIN Position on Control Switch W BK Black Negative Test Lead E Red Positive R Test Lead a lt 5410 High Pressure Switch HPS Y m ege fuu Compressor Delay Relay CDR LLLA CDR Terminals 3 W O and 5 W O Control Board K9 Connector Fig 1 3LIH K 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
50. n the control board receives 5VDC on K4 connector pin 4 W R the control starts the icemaking process b OFF When the control switch is in the OFF position the 5VDC circuits used for ice and drain are open and the unit is off c DRAIN When the control switch is in the DRAIN position the control switch closes a 5VDC circuit from control board K4 connector pin 1 W BK to control board K4 connector pin 2 W BK When the control board receives 5VDC on K4 connector pin 42 W BK the control board directs 24VAC to the drain valve and the drain valve energizes 35 IV Removal and Replacement of Components A 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 CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after the equipment is serviced Make sure that none have fallen into the storage bin Make sure all food zones in the icemaker and storage bin are clean after the icemaker is serviced For cleaning procedures see VI Cleaning and Maintenance When replacing evaporator assembly and water circuit components make sure there are no water leaks after the repair is complete A
51. ng clear of the agitator rotating inside of the storage bin 5 Disconnect BC connector from the back of the control box 6 Check for continuity across BC microswitch If BC large balance plate is not engaged and BC microswitch is open replace BC microswitch 7 Press and hold BC large balance plate While BC large balance plate is engaged check for continuity across BC microswitch If BC large balance plate is engaged and BC microswitch is open replace BC microswitch 8 Disengage BC large balance plate 9 Reconnect BC connector Remove the control box cover 10 Move the move the control switch to the ICE position then move the power switch to the ON position 11 Make sure the GM LED is on There is a delay of at least 5 seconds before the GM LED turns on after power up After the GM LED turns on press the SERVICE button on CB to bypass the 5 min ice purge timer WARNING Risk of electric shock Care should be taken not to touch live terminals COMP LED turns on 12 When Comp starts press and hold BC large balance plate 13 Comp and GM should de energize within 10 seconds Diagnosis If not and BC microswitch is found open and the appliance continues to run replace CB 14 Move the power switch to the OFF position Leave the control switch in the ICE position 15 Replace the storage bin cover and secure 16 Replace the control box cover left side top and front panels in their correct positions 1
52. of the O ring or mechanical seal 43 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 12 13 14 15 16 17 Install the O ring and mount the lower housing on the gear motor Install the lower part of the mechanical seal on the lower housing Lower the evaporator down and secure it to the lower housing Install the auger assembly with the upper part of the mechanical seal attached Replace the evaporator bracket in its correct position Ta se o Replace spout A spout B and the front cover of the storage bin in their correct positions 18 Move the power switch to the ON position then replace the panels in their correct positions 19 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 44 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 th
53. off and WV de energized If UFS is closed WV LED is off and GM LED is off replace CB If GM LED is on and GM is off confirm 115VAC at CB K1 2 BR to neutral W If 115VAC is not present check for loose connection from power switch If 115VAC is present check for 115VAC at CB K1 3 BK to neutral W If 115VAC is not present replace CB Diagnosis GM If 115VAC is present at CB K1 2 BR to neutral W check GM fuse GM capacitor GM windings and GM coupling between auger and GM Diagnosis CDR See II C 3 c Compressor Delay Relay 5 min Ice Purge Timer Circuit Once 5 min ice purge timer terminates freeze cycle begins 6 Freeze Cycle COMP LED is on 5 min ice purge timer terminates or SERVICE button pressed COMP LED turns on GM LED remains on Comp and FM energize GM and CDR 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 If COMP LED is off confirm 5 min ice purge timer has terminated Check for OVDC across CB K9 3 W O and CB K9 5 W O If 5VDC is present CDR contacts are open Check for 115VAC at CDR 7 O to CDR 8 W If 115VAC is present check CDR continuity between CDR 3 W O and CDR 5 W O If open replace CDR If closed and COMP LED remains off replace CB If COMP LED is on and Comp is off check for 115VAC at each CB X1 brown BR wire to neutral W
54. ot adjust Setting not used on this model When dip switch 7 is off 1 2 and 3 are ignored Factory set DCM 270BAH OS does not use a bin control with an infrared sensor The appliance uses a bin control with a mechanical microswitch for ice level control 3 Drain Frequency Control S1 dip switch 4 The appliance is factory set for optimum performance with the 1 in 1 drain cycle S1 dip switch 4 in the OFF position This setting allows for removal of sediment from the evaporator without interrupting the icemaking process 1 in 12 drain cycle is available S1 Dip Switch Setting Drain Timer Interval Drain Valve Open OFF 1 in 1 2 Seconds ON 1 in 12 11 Hours 45 Minutes 10 Minutes 33 4 Continuous Dispensing Timer S1 dip switch 5 amp 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 amp 6 out of the factory S1 Dip Switch Settin P Dispense Time default position 60 Seconds Note The ice dispense solenoid has an internal overload protector When set to No Limit the internal protector may open if ice dispense solenoid is energized longer than 3 to 4 min at one time Nes 5 Bin Control Selector S1 dip switch 7 The appliance is factory set with mechanical bin control operation No adjustment is required In the factory default position 51 dip sw
55. p cover in their original positions and secure Replace all panels in their original positions and secure Move the power switch to the ON position to start the automatic icemaking process 10 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 e 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 e When checking control board DC voltage 5VDC always place the red positive test lead from the multimeter to CB K5 pin closest to CB K4 connector See II C Control Board Check To speed up the diagnostic process the 5 min ice purge cycle may be bypassed by pressing the SERVICE button on the control board after the gear motor starts WARNING Risk of electric shock Care should be taken not to touch live terminals 1 Move the power switch to the OFF position then disconnect the power cord from the electrical outlet Remove the front top and left side panels Remove the control box COVer 2 Reconnect the power cord into the electrical outlet then move the power switch to the ON position 3 Move the control switch to the DRAIN position CB POWER OK LED and FLUSH drain
56. s 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 charging hoses to both high and low side access valves IMPORTANT The vacuum level and vacuum pump may be the same as those for current refrigerants However the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils 2 Turn on the vacuum pump Open the gauge manifold valves Never allow the oil in the vacuum pump to flow backwards 3 Allow the vacuum pump to pull down to a 29 9 Hg vacuum Evacuating period depends on pump capacity 37 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 6 A liquid charge is required for charging an R 404A system to prevent fractionation Place the service cylinder on the scales if the service cylinder is not equipped with a dip tube invert the service cylinder then place it on the scales Open the high side valve on the gauge manifold 7 Allow the system
57. tart the automatic icemaking process 41 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 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 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 9 Remove the allen head cap screws securing the evaporator to the lower housing 10 Lift off the evaporator 11 Inspect the mechanical seal and O ring prior to installing the new evaporator The mech
58. to charge with liquid until the proper charge weight is met 8 If necessary add any remaining charge to the system through the low side NOTICE To prevent compressor damage use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low side access valve with the icemaker running 9 Close the high and low side gauge manifold valves then disconnect the gauge manifold hoses 10 Cap the access valves to prevent a possible leak B Important Notes for Component Replacement NOTICE When replacing a component listed below see the notes to help ensure proper operation Component Notes S Install a new drier start capacitor and start relay Expansion Valve e Install a new drier 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 positions on the tube Secure the bulb with the clamp and holder then insulate it Upper and Inspect the upper bearing for wear See IV C 1 Upper Bearing Wear Check Replace if Lower Bearings necessary When replacing the upper bearing it is advised to also change the lower bearing at the same time Evaporator Install a new drier Inspect the mechanical seal and O ring prior to installing the new evaporator If worn cracked or scratched the mechanical seal should also be replaced Gear Motor Install a new gear motor capacitor 38 Drip R
59. w water safety timer fill timer check DV leaking by or open UFS See II E Float Switch Check and Cleaning Note Each time UFS closes 30 min freeze timer starts The 30 min freeze timer resets when UFS closes again If UFS does not close again within 30 min CB shuts down the unit and sounds a 5 beep alarm every 5 sec See II B LED Lights and Alarm Safeties 10 Shutdown Bin fills with ice activating BC microswitch Within 10 sec control board shutsdown unit Diagnosis Check that BC large balance plate is activated and not sticking Check BC microswitch continuity When BC large balance plate is down icemaking BC microswitch is closed When BC large balance plate is up BC microswitch is open If not replace BC microswitch If BC microswitch is open and Comp FM and GM do not de energize replace CB See II C Control Board Check Procedure Legend BC bin control CB control board CDR compressor delay relay Comp compressor CT control transformer DV drain valve FM fan motor GM gear motor LFS lower float switch UFS upper float switch WV inlet water valve 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 and 115VAC 3A GM breaker are good Check the S1 d
60. witch and power switch to the OFF positions then turn off the power supply before servicing Lockout Tagout to prevent the power supply from being turned back on inadvertently Maintenance Schedule esemy uws fa OOOO S Every 2 Air Filter Inspect Wash with warm water and neutral cleaner if dirty Weeks Monthly External Water Check for proper pressure and change if necessary Filters Appliance Exterior Wipe down with a clean soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up Clean any chlorine staining rust colored spots using a non abrasive cleaner Every 6 Icemaker and Clean and sanitize per the cleaning and sanitizing instructions provided in Months Storage Bin the instruction manual or maintenance label on the appliance Evaporator Wipe down with a clean cloth and warm water Dilute 0 82 fl oz 25 ml of a Condensate Drain 5 25 sodium hypochlorite solution chlorine bleach with 1 6 gal 6 0 1 of Pan and Gear warm water Slowly pour one cup of sanitizing solution into the evaporator Motor Drain Pan condensate drain pan Be careful not to overflow the pan This solution will flow down to the gear motor drain pan and out the drain line to sanitize these areas Repeat with a cup of clean water to rinse Icemaker Storage Check to make sure they are clear Bin and Drip Tray Drains Yearly Inlet Water Valve Close the water supply line shut off valve and drain the water system Clean an
Download Pdf Manuals
Related Search