Hoshizaki DCM-240 User's Manual
Contents
1. 11 Check for water leaks WATER VALVE 12 Replace the panels in their correct position STORAGE BIN ASSEMBLY WATER VALVE S SA FOR DISPENSE A RESERVOIR WATER VALVE FOR RESERVOIR WATER SUPPLY LINE DRAIN CAPPED DCM9404 8 REMOVAL AND REPLACEMENT OF FLOAT SWITCH WARNING 1 Fragile handle very carefully 2 If the Float Switch works poorly because of scale or other foreign matter install a filter or softener in the water supply line 1 Turn off the power supply 2 Close the Water Supply Line Shut off Valve 3 Remove the Drain Cap and drain out 4 Remove the panels 5 Cut the Float Switch leads at the wire connectors 6 Turn and unfasten the flanged top and remove the Float Switch 7 Install the new Float Switch ff swiTCH LEADS FLANGE e ll 8 Assemble the removed parts in the reverse order of which they were PLONE removed RESERVOIR COVER FLOAT SWITCH 9 Open the Water Supply Line Shut off Valve 10 on the power supply and check that the Float Switch works normally IV 17 9 REMOVALAND REPLACEMENT OF BINCONTROL SWITCH ASSEMBLY 1 Turn off the power supply 2 Remove the Top Panel 3 Remove the Storage Bin Cover 4 Remove the Bin Control Switch 5 Remove the Snap Pin and E ring and disassemble the Balance Plate A Balance Plate B and Shaft 6 Rotate the Inside Cover counterclockwise and re2. WATER VALVE BIN CONTROL SWITCH ICE MAKING TCH OAT SWITCH FL E a sjem 4 DCM 240BAB 20 WIRING DIAGRAN WIRE COLOR COD3 BR BROWN Y WAITE BX BLACK R RED ORANGE GY GRAY P PINK DBU DARK BLUE L3U LIGHT BLUZ VIOLET Y a 2 3 4 TIMER BOARD 11106 5 cian s L N BK POWER SWITCH DISPENSING SWITCH WATER SWITCH WATER YALY m LBU DEN NO ICE SWITCH THERMAL 7 _ PROTECTOR GEAR MOTOR 00 LOMFD START CAP FAN is ss WATER VALVE BIN CONTROL MAXING lt Sm FLOAT SWITCH DP EC RN 7 2 w o am o gt ea a DCM9404 DCM 240BAE Ill 21 f Gear Motor stops about 60 sec after Compressor stops WIRE COLOR CODE 115 120 80 1 BLACK P PINK BR BROWN R RED b UBU DARK BLUE Y VIOLET a aa W WHITE POWER SWITCH 7 FUSECISA LAMP d DISPENSING SWITCH 5 3 CE 0 9 DISPENSING 1 RELAY PROTECTOR X BIN an 5 CONTROL ES ICE BR MAKING E SWITCH CERES FLOAT SWITCH DCM 240BAA DCM9404 III 22 DCM9404 WIRE COLOR CODE BR BROWN W WHITE BK BLACK R RED O ORANGE GY GRAY P PINK DBU DARK BLUE LBU LIGHT BLU
3. HOSHIZAKI CUBELET ICE DISPENSER IV SERVICE INFORMATION CONTENTS PAGE ADJUSTMENT OF COMPONENTS s IV 1 1 ADJUSTMENT OF CONSTANT PRESSURE EXPANSION VALVE EXCEPTDOM OA0BAE oo cest iet on iso dator IV 1 HOW TO ADJUST acto terrenis eo det dis IV 1 b SUCTION TEMPERATURE iinn IV 1 c SUCTION PRESSURE I I 2 SERVICE DIAGNOSIS 20 414 IV 3 1 NO ICE PRODUCTION ccscsssccesscosececcsocssucssssssecsecerecsacsssecnscsscsasecnscsuscavseaseeseen IV 3 2 LOW ICE PRODUCTION III IV 5 3 FAULTY DISPENSER IV 6 c NR RM 7 REMOVAL AND REPLACEMENT OF COMPONENTS ene IV 8 1 SERVICE FOR REFRIGERANT IV 8 a REFRIGERANT RECOVERY 1401 IV 8 b EVACUATION AND IV 8 PUDE 9 3 REMOVAL AND REPLACEMENT OF IV 10 4 REMOVAL AND REPLACEMENT OF DRIER aaa 13 5 REMOVAL AND REPLACEMENT OF CONSTANT PRESSURE EXPANSION VALVE DCM 240BAA BAB AND THERMOSTATIC EXPANSION VALVE 2 0 buds fei 14 6 REM
4. CONTENTS PAGE ESPECIFICA 1 DOM 240BAA tii areas 1 2 0 2 k 3 1 SPECIFICATIONS 240 AC SUPPLY VOLTAGE 11576071 AMPERAGE 5 8 A CAT 104 F WT 80 MINIMUM CIRCUIT AMPACITY N A MAXIMUM FUSE SIZE N A u APPROXIMATE ICE PRODUCTION PER 24 HR Temp 89 900 2 10 55 0 lbs day kg day 0 225 1022 214 90 209 95 203 92 187 87 165 75 Reference without marks 209 95 205 93 196 89 192 87 168 76 SHAPE OF ICE Cubelet Compressed Flake ice ICE QUALITY Approx 90 Ice 90 70 Conductivity 200 ws cm APPROXIMATE STORAGE CAPACITY 8 8 lbs ELECTRIC WATER CONSUMPTION 90 F 70 F 70 F 50 F ELECTRIC W KWH 100 15 640 8 0 625 6 7 POTABLE WATER 23 12 0 27 12 0 gal 24HR gal 100 lbs EXTERIOR DIMENSIONS WxDxH 16 9 16 x 23 1 16 x 31 1 2 420 x 586 x 800 mm EXTERIOR FINISH Stainless Steel Painted Steel Top WEIGHT Net 141 lbs 64 Shipping 170 lbs 77 CONNECTIONS ELECTRIC Cord Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 MPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct driven Auger 80 W Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Bin Control Microswitch COMPRES
5. F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESS 10 113 PSIG We reserve the right to make changes in specifications and design without prior notice DCM9408 1 3 7 22 U B E L ET H ICE DIS D IS 5 E R G E NE RAL INF ORMA T IO N 1 CONSTRUCTION 2 OPERATION How works CONTENTS 4ee02444u44452080u4u4u4u492280u 7860 60 988 00869 69 0290089 92590492024024 08n00040000595409 1 CONSTRUCTION Hoshizaki Cubelet Dispenser models DCM 240BAA DCM 240BAB and DCM 240BAE include Water Supply Freezer Condensing Storage Dispensing and Control Assemblies DCM 240BAA BIN CONTROL SWITCH STORAGE BIN COMPRESSOR SWITCHES CONDENSER ICE CHUTE FAN PUSH LEVER RESERVOIR FREEZER EVAPORATOR GEAR MOTOR CONTROL BOX SUPPLY DRAIN INLET USTABLE LEGS OUTLET AIR FILTER POWER CORD Note Adjustable Legs Minimum height 4 Maximum height 5 3 Do not adjust exceeding the above recommendation DCM9404 1 1 DCM 240BAB DCM 240BAE BIN CONTROL SWITCH STORAGE BIN CONTROL BOX B 7 Pr A A COMPRESSOR ICE CHUTE SWITUHES CONDENSER FAN RESERVIOR AIR FILTER LOUVER FREEZER EVAPORATER WATER DRAIN OUTLET id ADJUSTABLE CONTROL BOX A Lepe GEAR MOTOR WATER SUPPLY INLET POWER SUPPLY CORD Note Adjustable Legs Minimum height 4 Maximum height 5 3 Do not adjust exc
6. FUSECISA M LAMP DISPENSING WATER SWITCH SWITCH 5 I DISPENSING 1 RELAY PROTECTOR ICE MAKING SWITCH a FLOAT SWITCH DCM 240BAA Step 2 Gear Motor starts DCM9404 10 5 L N WIRE COLOR CODE 45 BR BROWN W WHITE POWER SWITCH BK BLACK R RED nx FUSE ISA pp ORANGE d GY GRAY BU DARK BLUE DISPENSING SWITCH LBU LIGHT BLUE 2 WATER SWITCH MATER HS qs dis P ICE SWITCH WATER VALVE BIN CONTROL SWITCH ice MAKING SWITCH TIMER BOARD 1110 6 5 WATER CONTROLBRELAY wana _ 9 n I i DCM 240BAB DCM9404 11 WIRING DIAGRAM WIRE COLOR CODE BR BROWN Y MITE BX BLACK R RED Q ORANGE GY GRAY P PINK DBU DARK BLUE LBU LIGHT BLUE VIOLET TIMER BOARD 11106 5 115 120 60 1 L N BK T POWER SWITCH DISPENSING SWITCH VATER SWITCH WATER VALVE 2 LBU a2 ON 70 ICE SWITCH ICE DISPENSIN MOTOR d PROTECTOR m of 3 E Lal 4 S GEAR ADTOR R MOT PROTECTOR mo 1 GEAR MOTOR _ PROTECT RELAY gt WATER VALVE BIN CONTROL SWITCH ICE MAKING o WATER CONTROL 5 ES ms 2CM9404 DCM 240BAE III 12 Compressor starts abou
7. HOSHIZAKI CUBELET ICE DISPENSER MODEL DOM B4O SERVICE MANUAL DCM9404 CONTENTS SPECIFICATIONS 1 SPECIFICATIONS ll GENERAL INFORMATION 1 CONSTRUCTION 2 OPERATION How it works TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 2 WIRING DIAGRAM _ 3 SEQUENCE OF ELECTRICAL CIRCUIT 4 PERFORMANCE DATA IV SERVICE INFORMATION ADJUSTMENT OF COMPONENTS SERVICE DIAGNOSIS REMOVAL AND REPLACEMENT OF COMPONENTS V MAINTENANCE AND CLEANING INSTRUCTIONS 1 PREPARING THE ICE DISPENSER FOR LONG STORAGE 2 CLEANING INSTRUCTIONS 3 MAINTENANCE DCM9404 FOREWORD This Service Manual contains the specifications and information in regard to transporting unpacking installing operating and servicing the machine You are encouraged to read it thoroughly in order to obtain maximum performance You will find details on the construc tion installation and maintenance If you encounter any problem not covered in this Service Manual feel free to contact Hoshizaki America Inc We will be happy to provide whatever assistance is necessary Keep this Service Manual handy and read it again when questions arise HOSHIZAKI AMERICA INC 618 HIGHWAY 74 SOUTH PEACHTREE CITY GEORGIA 30269 U S A PHONE 404 487 2331 HOSHIZAKI ELECTRIC CO LTD TOYOAKE AICHI JAPAN PHONE 0562 97 2111 TELEX NO 04486 514 HOSHI J HOSHIZAKI CUBELET ICE DISPENSER I SPECIFICATIONS 9404
8. PROTECTOR NM 4 lc sb suc reps petram 1 7 8 TIMER BOARD 111065 po ee me mee 240 DCM9404 III 7 WIRING DIAGRAM 1 N WIRE COLOR CODS BK BR BROWN A Y WITE POWER SWITCH BK BLACK R RED 0 ORANGE LANP GY GRAY BLUE DISPENSING SWITCH LBU LIGHT BLUE gt WATER E aha VALVE VIOLET mW m9 o o Do ICE SWITCH SOLENOID RELAY MOTOR pal PROTECTOR 1 N 5 O 2 THERMAL 0 TT GEAR MOTOR O R PROTECTOR gt eh Se WATER VALVE BIN CONTROL SWITCH ICE MAKING SWITCH TIMER BOARD 11108 5 DCM 240BAE DCM9404 8 b When Reservoir has been filled up Gear Motor starts immediately WIRE COLOR CODE 115 120 80 1 BK BLACK PINK BK BR BROWN R RED DBU DARK BLUE Y VIDLET UNE LINE LBU LIGHT BLUE W WHITE POWER SWITCH 8 ORANGE FUSECISA BK LAMP T DISPENSING WITCH 5 9 Vice 10 5 DISPENSING 2 RELAY am PROTECTOR TIMER s 3c i do 65 BIN CONTROL CE MAKING SWITCH E FLOAT SWITCH DCM 240BAA Step 1 Reservoir filled up DCM9404 9 WIRE COLOR CODE BLACK P PINK BR BROWN RED DBU DARK BLUE Y VIOLET LBU LIGHT BLUE W WHITE 8 ORANGE L 115 120 80 1 K W LINE LINE POWER SWITCH
9. THERMAL 777777777 z h GEAR MOTOR lt gt TIMER BOARD FL 11106 5 3 OAT SWITCH am s s a k o o w o Sa ae a sie e 240 DCM9404 III 29 115 120 60 1 WIRING DIAGRAN N WIRE COLOR CODE BK 4 POWER SWITCH BLACK R RED O ORANGE GY GRAY PINK DBU DARK BLUE LBU LIGHT BLUE VIOLET eo Q O WATER VALVE BIN CONTROL SWITCE ice MAKING la 1 9 js TIMER BOARD 11106 5 DCM 240BAE III 30 i When water pressure gets low black and dark blue leads of Float Switch open Compressor stops about 90 sec later and then Gear Motor stops about 60 sec after Compressor stops WIRE COLOR CODE 115 120 80 1 BK BLACK P PINK BR BROWN R RED NE une DBU DARK BLUE V VIQUET ie POWER SWITCH FUSECISA LAMP DISPENSING SWITCH DISPENSING PROTECTOR BIN CONTROL ICE MAKING SWITCH D O O 0D FLOAT SWITCH DCM 240BAA DCM9404 Ill 31 imma L N WIRE COLOR CODE BR BROWN i W WHITE POWER SWITCH BLACK R RED ax FUSE ISA pp O ORANGE Ns GY GRAY sis P PINK DBU DARK BLUE DISPENSING SWITCH WATER SWITCH WATER VALVE LBU LIGHT BLUE 2 eu VIOLET Q O O4 00 O COM NO P ICE SWITCH LENOID M
10. 100 635 645 645 APPROXIMATE WATER 10 26 9 102 25 6 97 25 1695 CONSUMPTION PER 24 HR 80 25 1095 24 6 93 24 3 92 89 23 5 89 23 0080 22 5 85 gal day 2 day 100 20 30 77 20 1070 19 8 75 EVAPORATOR OUTLET TEMP 70 3 3 EN 16 1 16 0 16 1 200080 5 5 5 8 CI CIS C15 13 3 90 23 26 19 25 14 11 5 3 3 7 2 3 9 C10 8 3 100 32 32 28 CO 0 0 2 2 HEAD PRESSURE 70 101 7 1 108 7 6 1074 5 80 121 8 5 122 8 6 121 8 5 90 134 9 4 131 9 2 1350 5 PSIG kg cniG 100 1571 0 1571 0 157 11 0 TOTAL OF REJECTION 3980 BTU h AT 90 WT 70 P Note The data without xmarks should be used for reference DCM9404 III 34 DCM9404 DCM 240BAB APPROXIMATE ICE PRODUCTION PER 24 HR lbs day kg day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR gal day 2 day EVAPORATOR OUTLET TEMP Cf HEAD PRESSURE PSIG kg cafG TOTAL HEAT OF REJECTION Water Temp pw Ambient Temp 225 102 214 97 209 95 209 95 205 93 203 92 196 89 102 87 187 85 170 168 76 165 75 25 6 97 24 6 93 23 0 87 20 1C 76 26 9 102 25 1C 95 23 5 89 20 3 TT 25 1 95 24 3 92 22 5 85 19 8 75 3 516 4 5 15 1513 9 95975 14 17 C4 25
11. 75 24 lbs day kg day Reference without marks SHAPE OF ICE Cubelet Compressed Flake Ice ICE QUALITY Approx 90 Ice 90 70 Conductivity 200 APPROXIMATE STORAGE CAPACITY 8 8 Ibs ELECTRIC amp WATER CONSUMPTION 90 F 70 70 F 50 ELECTRIC W CkWH 100 lbs 770 8 0 140 6 1 POTABLE WATER 34 2 0 27 12 0 gal 24HR gal 100 185 EXTERIOR DIMENSIONS WxDxH 16 9 16 x 23 1 16 x 31 1 2 420 x 586 x 800 mm EXTERIOR FINISH Stainless Steel Painted Steel Top WEIGHT Net 143 lbs 65 kg Shipping 161 Ibs 73 kg CONNECTIONS ELECTRIC Cord Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct driven Auger 80 W Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Bin Control Microswitch COMPRESSOR Hermetic 400 W Model CF180J1N 1U CONDENSER Air cooled Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Constant Pressure Expansion Valve REFRIGERANT CHARGE R22 11 602 330 DESIGN PRESSURE High 420 PSIG Low 230 PSIG COMPRESSOR PROTECTION Auto reset Overload Protector GEAR MOTOR PROTECTION Manual reset Circuit Breaker REFRIGERANT CIRCUIT PROTECTION N A LOW WATER PROTECTION Float Switch and Timer ACCESSORIES REQUIRED N A OPERATING CONDITIONS VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100
12. REPLACEMENT OF PRESSURE SWITCH 240BAE ONLY IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the Control Box Cover and disconnect the terminals 5 Remove the Pressure Switch using brazing equipment 6 Braze the new Pressure Switch with nitrogen gas flowing at the pressure of 3 4 PSIG 7 Install the new Drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 10 Replace the terminals and the Control Box Cover in their correct position 11 Replace the panels in their correct position 12 Turn on the power supply DCM9404 IV 15 7 REMOVAL AND REPLACEMENT OF WATER VALVE 1 Turn off the power supply 2 Close the Water Supply Line Shut off Valve 3 Remove the Drain Cap and drain out 4 Remove the panels 5 Remove the valve outlet tubing by releasing the Clamp 6 Remove the Fitting Nut and the Water Valve 7 Install the new Water Valve 8 Assemble the removed parts in the reverse order of which they were removed 9 Open the Water Supply Line Shut off Valve PITTING NUT 72 10 on the power supply SCREW
13. c Fuse 1 Blown out 1 Check for short circuit and replace DCM 240BAE 1A Control Box a Water Supply Line 1 Shut off Valve closed 2 Water Valve 1 Open o O operates but no 2 Water supply OFF 2 Check and get ice is produced recommended pressure 15A Next to Power b Water Valve 1 Clogged c Water Control Relay 1 Bad contacts Terminal 1 Check for continuity and Nos 4 and 6 replace 2 Coil winding opened d Timer 1 Bad contacts 1 Check for continuity and replace 3 Tighten 3 Tighten 4 Defective 3 Compressor will i not start 1 Replace b Timer 1 Bad contacts X2 or grounded replace opene 3 Tighten replace Capacitor a Gear Motor 1 Motor winding opened d b Timer 1 Bad contacts X1 1 Check for continuity and Re replace 2 X1 Relay coil winding 2 Replace opened 4 Gear Motor will not start Motor Protector 1 Bad contacts 1 Check for continuity and replace Rela la 3 Tighten Protect Relay 1 Check for continuity and replace 1 Bad contact 1 Check for continuity and replace e Capacitor 1 Defective 1 Replace 2 Coil winding opened d Protector DCM9404 POSSIBLE CAUSE REMEDY a Fan Motor 3 Check for loose connection or open and replace PROBLEM 5 Fan Motor will not start 4 Fan blade bound 4 Check and replace b
14. the Expansion Valve Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the Insulation covering the Expansion Valve Bulb DCM 240BAE only 5 Remove the two Clamps securing the Expansion Valve Bulb DCM 240BAE only 6 Remove the Expansion Valve Cover 7 Disconnect the Expansion Valve using brazing equipment 8 Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 3 4 PSIG WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 250 F 9 Install the new Drier 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 11 Evacuate the system and charge it with refrigerant See the Nameplate forthe required refrigerant charge 12 Place the Expansion Valve in position 13 Attach the Expansion Valve Bulb to the low side line and secure them with the Clamps at the maximum torque of 6 5 DCM 240BAE only IV 14 14 Cover the Expansion Valve Bulb tightly with the Insulation DCM 240BAE only 15 Place the new set of Expansion Valve Covers in position 16 Replace the panels in their correct position 17 Turn on the power supply 6 REMOVAL AND
15. 0BAA FAN MOTOR ASSEMBLY CONDENSER DRIER CLAMP DCM 240BAA CLAMP DCM 240BAB FAN MOTOR SCREW T BRACKET a SCREW FAN BLADE DCM9404 IV 11 DCM 240BAE CHARGE TUBE ss 4 8 Y PROCESS PIPE lt gt COMPRESSOR SUCTION PIPE ACCESS VALVE MUFFLER EVAPORATOR DISCHARGE PIPE CLAMP PRESSURE SWITCH THERMOSTATIC EXPANSION VALVE CONDENSER ACCESS VALVE FAN MOTOR ASSEMBLY DRIER DCM9404 IV 12 4 REMOVAL AND REPLACEMENT OF DRIER 1 Turn off the power supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the Clamp securing the Drier and pull the Drier toward you for easy service 5 Remove the Drier using brazing equipment 6 Install the new Drier in the direction of the refrigerant flow Use nitrogen gas at the pressure of 3 4 PSIG when brazing the tubings 7 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 8 Secure the Drier with the Clamp 9 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 10 Replace the panels in their correct position 11 Turn on the power supply DCM9404 IV 13 DCM9404 5 REMOVAL AND REPLACEMENT OF CONSTANT PRESSURE EXPANSION VALVE DCM 240BAA BAB AND THERMOSTATIC EXPANSION VALVE DCM 240BAE IMPORTANT Sometimes moisture in the refrigeration circuit exceeds the Drier capacity and freezes up at
16. 9 9 9 E S10 99 8 3 32 0 1017 1 108 7 6 107 7 5 121 8 5 122 8 6 12168 5 134 9 4 13119 2 135 9 5 157 11 0 157 11 0 157 11 0 3980 BTU h 90 WT 70 Note The data without marks should be used for reference III 35 240 APPROXIMATE Ambient ICE PRODUCTION PER 24 HR 290 131 270 122 240 108 200 90 lbs day kg day APPROXIMATE ELECTRIC CONSUMPTION watts 34 6 131 32 2 122 28 5 108 23 8 90 14 9 6 16 8 9 17 6 8 0 19 4 7 0 221 15 6 255 18 0 285 20 1 324 22 8 28 2 0 30 2 1 31 2 2 34 2 4 APPROXIMATE WATER CONSUMPTION PER 24 HR gal day day EVAPORATOR OUTLET TEMP R HEAD PRESSURE PSIG kg cx G SUCTION PRESSURE PSIG kg cmG TOTAL HEAT OF REJECTION Note The data without marks should be used for reference III 36 DCM9404 Water Temp 280 127 250 113 230 104 180 82 33 5 127 29 8 113 27 5 104 21 7 82 14 9 6 16 8 9 16 9 8 4 19 4067 0 227 16 0 251 1821 282 19 9 320 22 5 28 2 0 30 2 1 3102 2 34 2 4 BTU h AT 90 WT 70 P 210 122 230 104 200 90 165 75 32 26122 21 5 104 23 8 90 19 8 75 14 5 9 7 16 8 9 16 8 5 15 5655 231 16 3 258 18 2 291 20 5 311 22 3 30 2 1 30 2 1 31 2 2 34 2 4 Z gt
17. ANGE a GY GRAY P PINK DBU DARK BLUE LBU LIGHT BLUE V VIOLET ICE DISPENSING RELAY R PROTEC 9 a m WATER VALVE BIN CONTROL SWITCH ice MAKING SWITCH 4 I i TIMER BOARD FLOAT SWITCH 11106 5 a 02 24 RE 3 NE R DCM 240BAB DCM9404 III 26 lt m af WIRING DIAGRAW L N WIRE COLOR CODE BK oe POWER SWITCH BK BLACK j R RED O ORANGE GY GRAY P PINK DBU DARK BLUE LBU LIGHT BLUE VIOLET 1 cm P WATER VALVE BIN CONTROL SWITCH ice MAKING SWITCH TIMER BOARD 11106 5 amp e e DCM 240BAE DCM9404 III 27 h Dispensing water Control still tripped WIRE COLOR CODE I 115 120 80 1 BK BLACK P PINK BR BROWN R RED W DBU DARK BLUE T LA LT W WHITE POWER SWITCH FUSECISA BK LAMP Uy DISPENSING WATER VALVE xis BU BR SOLEN DID VANE Vig 1 5 o Loi DISPENSING 2 p 1 EAR PROTECTOR 9 30 T ir Thir R BIN ave la FLOAT SWITCH DCM 240BAA 2 9404 28 L N WIRE COLOR CODE BR BROWN W WHITE POWER SWITCH BK BLACK R RED ay 15 pp O ORANGE NA GY GRAY P PINK DBU DARK BLUE LBU LIGHT BLUE V VIOLET
18. E V VIOLET pore od 7 8 omi TIMER BOARD 1110 8 5 us A L N BK POWER SWITCH FUSE ISA pp de LAMP DISPENSING SWITCH i WATER SWITCH WATER VALVE LBU FG COM NOI P ICE SWITCH THERMAL GEAR MOTOR 00 PROTECTOR WATER VALVE BIN CONTROL SWITCH ICE MAKING DCM 240BAB III 23 WIRING DIAGRAM WIRE COLOR CODE BR BROWN Y WHITE BK BLACK R RED 0 ORANGE GY GRAY PINK DBU DARK BLUE LBU LIGHT BLUE Y VIOLET TIMER BOARD 11106 5 69 fi af L N BK 1 POWER SWITCH DISPENSING SWITCH WATER SWITCH WATER VALVE 2 180 QD vO TNO P ICE SWITCH SOLENOID MOTOR p RBT ES PROTECTOR THERMAL 777 p PROTECTOR GEAR MOTOR 00 CAP OMFD Ce WATER VALVE BIN CONTROL SYITCH c MAKING SWITCH DCM 240BAE III 24 9 Dispensing ice Bin Control still tripped WIRE COLOR CODE BK BLACK P PINK W BR BROWN R RED LINE LI E DBU DARK BLUE V VIOLET LBU LIGHT BLUE W WHITE 1 pir POWER SWITCH FUSECISA DISPERSING SWITCH WATER SWITCH CONTROL _ emo iro uli MAKING SWITCH 1 Oo di gt Se FLOAT SWITCH DCM 240BAA DCM9404 25 L N WIRE COLOR CODE BK BR BROWN W WHITE POWER SWITCH BK BLACK R RED FUSE I5A pr O OR
19. EN WATER VALVE BIN CONTROL SWITCH ice MAXING o aas WATER CONTROL RELAY RIT n DCM9404 DCM 240BAE 15 DCM9404 d Ice making process continues WIRE COLOR CODE 115 120 50 1 BK BLACK P PINK BR BROWN RED K DBU DARK BLUE V VIOLET 1 LBU LIGHT BLUE W WHITE POWER SWITCH FUSECI5A BK LAMP ly DISPENSING 0 ORANGE SWITCH 5 ice 10 5 DISPENSING ia Rear PROTECTOR START 100MFD R LBU 30MF STARTER MOT PROTECTOR BIN CONTROL ot s MAKING SWITCH FLOAT SWITCH DCM 240BAA Ill 16 WIRE COLOR CODE BR BROWN W WHITE BK BLACK R RED O ORANGE GY GRAY P PINK DBU DARK BLUE LBU LIGHT BLUE V VIOLET TIMER BOARD 11106 5 4 DCM9404 L N BK 1 POWER SWITCH DISPENSING SWITCH WATER SWITCH WATER VALVE SF es LBU COM NO P ICE SWITCH FUSE 154 pp D THERMAL U UU UI UI PROTECTOR GEAR MOTOR o OME D WATER VALVE BIN CONTROL SWITCH ICE MAKING FLOAT SWI i WATER CONTROLBRELAY es E DCM 240BAB Ill 17 DCM9404 gt WIRING DIAGRAM L N COLOR CODE BK BROWN Y WHITE POWER SWITCH BLACK i BX ORANGE GY GRAY LANP P PINK DBU DARK BLUE DISPENSING SWITCH
20. LBU LIGHT BLUE 2 WATER SWITCH WATER VALVE Y VIOLET 2 omo ICE SWITCH i SOLENOID MOTOR PROTECTOR 9 a A GEAR m OR O CAP TECT 10 m OMFD WATER VALVE BIN CONTROL SWITCH ick MAKING 1 2 3 4 TIMER BOARD 111085 9 WATER CONTROLBRELAY Ea 1 DCM 240BAE Ill 18 DCM9404 e Bin Control Switch tripped Compressor stops about 90 sec later WIRE COLOR CODE L 115 120 B0 1 BK BLACK P PINK bi BR BROWN R RED DBU DARK BLUE Y VIOLET LINE LIN LBU LIGHT BLUE W WHITE 8 ORANGE POWER SWITCH FUSECISA LAMP DISPENSING WATER SWITCH SWITCH ICE SWITCH 5 9 ICE 10 6 DISPENSING 1 RELAY PROTECTOR R 1 13 15 1 CONTROL AT ICE BR MAKING 2 SWITCH t one De FLOAT SWITCH DCM 240BAA Ill 19 WIRE COLOR CODE BR BROWN W WHITE BK BLACK R RED ORANGE GY GRAY P PINK DBU DARK BLUE LBU LIGHT BLUE V VIOLET TIMER BOARD 11106 5 q DCM9404 us gt L N BK 1 POWER SWITCH PUSE 154 ITCH WATER SWITCH WATER VALY WC JNO y ICE SWITCH DISPENSING SW MOTOR opp ICE DISPENSING R PROTECTOR I E o 10 THERMAL GEAR MOTOR 0 CAP TS s
21. OR m m d WATER VALVE BIN CONTROL SWITCH ICE MAKING TIMER BOARD 11106 5 OAT SWITCH FL F DCM9404 III 4 240 kasa 115 120 60 1 NES WIRING DIAGRAN N WIRE CODE BK BR BR W WHITE POWER SWITCH BK BLACK 5 ORANGE BK GY GRAY LAMP BLUE DISPENSING SWITCH LBU LIGHT BLUE WATER ae PATER VALVE VIOLET P NO i D ICE SWITCH SOLENOID 0 c MOTOR PR 69 pos STUCK GEAR MOTOR Mo WATER VALVE BIN CONTROL SWITCH ICE MAKING SWITCH TIMER BOARD 11106 5 DCM9404 II 5 3 SEQUENCE OF ELECTRICAL CIRCUIT a When Power Switch and Ice Making Switch are moved to position water starts to be supplied to Reservoir WIRE COLOR CODE 115 120 80 1 BK BLACK P PINK BR BROWN R RED URE me DRU DARK BLUE Y VIOLET LBU LIGHT BLUE W WHITE pes POWER SWITCH FUSECISA O ud LAMP T DISPENSING SWITCH PROTECTOR BIN CONTROL MAKING SWITCH FLOAT SWITCH DCM 240BAA DCM9404 Ill 6 le 115 120 60 1 L N WIRE COLOR CODE BK BR BROWN W WHITE POWER SWITCH BK BLACK 0 ORANGE GY GRAY a P PINK DBU DARK BLUE DISPENSING SWITCH WATER SWITCH WATER VALVE LBU LIGHT BLUE V VIOLET P LBU CO NO y P ICE SWITCH NOID y SOLENO THERMAL 777777705 PROTECTOR GEAR MOTOR DO D
22. OTOR PROTECTOR R PROTECTOR Aer a oy THERMAL 2755 3 25 GEAR MOTOR o PROTECTOR 7 1 S 2 lt lt M FUSE 1A Kav a dl WATER VALVE BIN CONTROL SWITCH tcp MAKING Ns 4 i TIMER BOARD FLOAT SWITCH 1101065 3 DCM 240BAB DCM9404 III 32 WIRING DIAGRAW WIRE COLOR CODE BR BROWN Y HITE 8X BLACK R RED 0 ORANGE GY GRAY PINK D3U DARK BLUE L3U LIGHT BLUE V VIOLET S R 646 la 31 3 4 TIMER BOARD 1165 iran L N BK 1 POWER SWITCH LAN DISPENSING SWITCH VATER SWITCH WATER VALVE 180 DM NO Pj ICE SWITCH SOLENOID C O Of DISPENSINO MOTOR EA E C s 4 2 THERMAL gt GEAR MOTOR 0 0 WATER VALVE BIN CONTROL SWITCH MAKING m s s a s m s 9404 DCM 240BAE III 33 _4 PERFORMANCE DATA DCM 240BAA APPROXIMATE ICE PRODUCTION PER 24 HR Ambient Water Temp 225 102 214 97 209 99 80 2090 95 205 93 203 92 90 196 89 192 87 187 85 lbs day kg day 100 110 77 168 76 165 15 APPROXIMATE ELECTRIC O gt CONSUMPTION watts
23. OVAL AND REPLACEMENT OF PRESSURE SWITCH DCM 240BAE ONLY ccecccssssesccucccsecssecsvecsuscsucssuscsusssusssucsssessucssnesaeessecsssense IV 15 7 REMOVAL AND REPLACEMENT OF WATER IV 16 8 REMOVAL AND REPLACEMENT OF FLOAT SWITCH IV 17 9 REMOVAL AND REPLACEMENT OF BIN CONTROL SWITCH ASSEMBLY IV 18 10 REMOVAL AND REPLACEMENT OF STORAGE BIN ASSEMBLY IV 19 11 REMOVAL AND REPLACEMENT OF AGITATOR AND DRIP RING IV 21 12 REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY DCM9404 DCM9408 ADJUSTMENT OF COMPONENTS 1 CONSTANT PRESSURE EXPANSION VALVE EXCEPT DCM 240BAE Since the Constant Pressure Expansion Valve is factory adjusted to the ideal setting no adjustment is required Should an adjustment be required for some reason perform the adjustment carefully in compliance with the following procedures Note DCM 240BAE employs an unadjustable Thermostatic Expansion Valve R22 27 33 PSIG a HOW TO ADJUST The Adjust Screw is visible when the Cap on the end has been removed To increase the refrigerant flow turn the Adjust Screw clockwise To decrease the refrigerant flow turn the Adjust Screw counterclockwise IMPORTANT 1 Do not turn the Adjust Screw more than 90 degrees 2 Wait for 2 or 3 minutes from an adjustment to another in order to stabilize the system Adjust carefully in terms of overa
24. SOR Hermetic 400 W Model CL50J 1U CONDENSER Air cooled Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Constant Pressure Expansion Valve REFRIGERANT CHARGE R12 8 8 oz 250g DESIGN PRESSURE High 235 PSIG Low 140 PSIG COMPRESSOR PROTECTION Auto reset Overload Protector GEAR MOTOR PROTECTION Manual reset Circuit Breaker REFRIGERANT CIRCUIT PROTECTION N A LOW WATER PROTECTION Float Switch and Timer ACCESSORIES SUPPLIED Spare Fuse REQUIRED N A OPERATING CONDITIONS VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESS 10 113 PSIG We reserve the right to make changes in specifications and design without prior notice DCM9408 7 1 DCM 240BAB AC SUPPLY VOLTAGE 115 60 1 AMPERAGE 5 8 CAT 104 F WT 80 MINIMUM CIRCUIT AMPACITY N A MAXIMUM FUSE SIZE N A APPROXIMATE ICE PRODUCTION Ambient Water Temp F PER 24 HR Temp lbs day kg day 70 225 102 209 95 196 89 Reference without marks 170 17 SHAPE OF ICE Cubelet Compressed Flake Ice ICE QUALITY Approx 90 X Ice 90 70 Conductivity 200 us cm APPROXIMATE STORAGE CAPACITY 8 8 lbs ELECTRIC amp WATER CONSUMPTION 90 F 70 70 50 ELECTRIC W CkWH 100 lbs 640 8 0 625 6 T POTABLE WATER 23 12 0 27 12 0 gal 24HR gal 100 165 EXTERIOR DIMENSIONS WxDxH 16 9 16 x 23 1 16 x 31 1 2 420 x 586 x 800 m
25. Timer 1 Check for continuity and Rela replace 2 X2 Relay coil winding 2 Replace opened a Water Supply 1 Water failure or 1 Wait till water is supplied pressure too low or adjust the pressure range within 7 113 PSIG 2 Shut off Valve closed or A restricted 6 No water or poor flow b Water Valve 1 Clogged filter 2 Coil winding opened Float Switch 1 Contacts fused 1 Bad contacts Terminal Nos 1 and 5 replace Terminal Nos 3 and 5 replace f Ice Making Switch 1 OFF position 2 Check for continuity and replace d Water Control Relay 1 Install 7 dispenser will a Float Switch 1 Contacts fused not stop even if out of water 2 Clogged b Water Control Relay 1 Contacts fused 1 Replace Terminal Nos 4 and 6 DCM9404 2 LOW ICE PRODUCTION refrigeration Condenser Circuit 2 Bad ventilation 2 Remove anything blocking vents 1 Check and adjust See b Constant Pressure 1 Low side pressure or Expansion Valve temperature exceeding ADJUSTMENT OF DCM 240BAA BAB the limit COMPONENTS 1 CONSTANT PRESSURE detector Reweld leak 2 Overcharged replace drier and charge e Compressor Motor 1 Overload Protector 1 Check Condenser and Protector stops Compressor Fan Motor intermittently EXPANSION VALVE c Thermostatic 1 Low side pressure or 1 Sec
26. ace 3 Ice keeps being dispensed a Shutter 1 Faulty adjustment 1 With Shutter closed lock Shutter in place by securing with two screws at the lower part of Solenoid and two screws under Solenoid b Ice Switch and 1 Replace Dispensing Switch 2 Loosen two screws and DCM 240BAA onl secure Switch in place C Working Bar 1 Smooth the hole on the DCM 240BAA only Lower Front Panel panel 2 Loosen screw so it can too tight move smoothly DCM9404 4 OTHERS 1 Ice dispenser will not stop even if filled with ice POSSIBLE CAUSE a Bin Control Switch 1 Contacts fused 2 Out of position 1 Contacts fused 1 Defective 1 Water pressure too 1 If pressure is consistently igh too high install a reducing valve 1 Cannot close 1 Clean or replace b Water Control Rela Timer 2 Reservoir a Water Supply overflows Water will not stop b Water Valve c Float Switch 1 Bad contacts Red and black leads replace 2 Defective 1 Coil winding opened 2 Bad contacts Terminal 2 Check for continuity and Nos 1 and 3 replace d Water Control Relay 8 Much water drains a Mechanical Seal 1 Dirt stuck on seal 1 Clean or replace from Gear Motor Normally less than surface Drain Pipe 0 017 fl oz hour 4 Abnormal noise a Fan Motor 2 Fan blade deformed 2 Replace fan blade 3 Fa
27. ain Cap Fig 1 0 9404 IMPORTANT Before operating the dispenser next time check that the Drain Valve is closed and open the Water Supply Line Shut off Valve Note When shutting off the ice dispenser at sub freezing temperatures run the ice dispenser with the Water Supply Line Shut off Valve closed and blow out the water inlet line by using air pressure gt Flexible Hose Shut off Valve Drain Valve Air or CO2 Fig 2 2 CLEANING INSTRUCTIONS WARNING 1 HOSHIZAKI recommends cleaning this unit at least twice a year More frequent cleaning however may be required in some existing water conditions 2 To prevent injury to individuals and damage to the ice dispenser do not use ammonia type cleaners 3 Always wear liquid proof gloves for safe handling of the cleaning and sanitizing solution This will prevent irritation in case the solution contacts with skin a CLEANING PROCEDURE 1 Close the Water Supply Line Shut off Valve 2 Dilute approximately 6 fl oz of a recommended cleaner LIME A WAY manufactured by Economics Laboratory Inc with 1 gal of water 3 Move the Ice Making Switch located on the left of the Middle Front Panel to the OFF position 4 Move the Ice Switch located on the right of the Middle Front Panel to the ON position and the Water Switch to the OFF position 5 Press the Push Lever or Push Button to dispense ice andremove allice fr
28. cesececssececucsarecssesasenssenesensesnneensensee V 7 3 MAINTENANCE DCM9404 1 PREPARING THE ICE DISPENSER FOR LONG STORAGE IMPORTANT When shutting off the ice dispenser for an extended time drain out all water from the water line and remove the ice from the Storage Bin The Storage Bin should be cleaned and dried Drain the ice dispenser to prevent damage to the water supply line at sub freezing temperatures using air or carbon dioxide Shut off the ice dispenser until the proper ambient temperature is resumed 1 Close the Water Supply Line Shut off Valve and open the Drain Valve DCM 240BAA 2 Move the Ice Making Switch located on the left ofthe Middle Front Panel tothe OFF position 3 Move the Ice Switch located on the right of the Middle Front Panel to the ON position Move the Water Switch to the OFF position ush Lever 4 Press the Push Lever or Push Button for ice dispense and remove all ice from the Storage Bin Drain Cap 5 Removethe Drain Cap anddrain the Reservoir and Freezer Water System See Fig 1 6 Replace the Drain Cap in its correct position DCM 240BAB 240 7 Move the Ice Switch to the OFF Indicator Lamp Ice Switch position Push Button f Ice Maki 8 Move the Power Switch located on n i the left bottom of the Middle Front Panel to the OFF position Water Switch 9 Unplug the ice dispenser Fuse DCM 240BAB Power Switch Dr
29. charge will damage the Compressor 7 Turn on the ice dispenser when charging speed gets slow Turn off the ice dispenser when the Low side Gauge shows approximately 0 PSIG Do not run the ice dispenser at negative pressures Closethe Low side Valve whenthe Service Cylinder gets empty 8 Repeat the above steps 4 through 7 if necessary until the required amount of refrigerant has entered the system 9 Close the Refrigerant Access Valve and disconnect the Hoses and Service Manifold 10 Cap the Access Valve to prevent a possible leak DCM9404 IV 8 2 BRAZING DANGER 1 Refrigerant R12 or R22 itself is not flammable explosive and poisonous However when exposed to an open flame R12 or R22 creates Phosgene gas hazardous in large amounts 2 Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere 3 Do not use silver alloy or copper alloy containing Arsenic 4 In its liquid state the refrigerant can cause frostbite because of the low temperature DCM9404 IV 9 9404 3 REMOVAL AND REPLACEMENT OF COMPRESSOR IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply 2 Remove the panels 3 Remove the Terminal Cover on the Compressor and disconnect the Compressor Wiring 4 Recover th
30. e refrigerant and store it in an approved container 5 Unsolder and disconnect the Discharge and Suction Pipes from the Compressor WARNING When repairing a refrigerant system be careful not to let the burner flame contact the lead wires or insulation 6 Remove the Hold down Bolts Washers and Rubber Grommets 7 Slide and remove the Compressor Unpack the new Compressor package Install the new Compressor 8 Attach the Rubber Grommets of the prior Compressor 9 Sandpaper the Suction Discharge and Process Pipes 10 Place the Compressor in position and secure it using the Bolts and Washers 11 Remove plugs from the Suction Discharge and Process Pipes 12 Braze the Process Suction and Discharge Pipes Do not change this order with nitrogen gas flowing at the pressure 3 4 PSIG 13 Replace the Drier 14 Check for leaks using nitrogen gas 140 PSIG and soap bubbles IV 10 15 Connect the Compressor Wiring to the Compressor and replace the Terminal Cover 16 Evacuate the system and charge it with refrigerant See the Nameplate forthe required refrigerant charge 17 Replace the panels in their correct position 18 Turn on the power supply PROCESS TUBE TS COMPRESSOR SUCTION LINE 7 7 yy DCM 240BAB 22 2 DISCHARGE LINE lt tad Sal DCM 240BAA DCM 240BAB i CHARGE TUBE CONSTANT PRESSURE ab EXPANSION VALVE SUCTION LINE DCM 24
31. eeding the above recommendation DCM9404 1 2 2 OPERATION How it works Water flows from the potable water source through the Water Supply Line Shut off Valve enters at the Water Inlet fitting and into the Water Reservoir The Water Reservoir functions to maintain a constant water level inside the Freezer Assembly Water from the Water Reservoir enters at the bottom of the Freezer Heat is removed by the refrigeration process and ice forms inside the Freezer stainless steel Auger located inside the Freezer is direct driven by the Gear Motor and the rotating Auger carries the ice upward to the end of the Auger where excess water is pressed out of the ice as the ice is extruded and broken into cubelet ice compressed ice and then pushed out into the Storage Bin Moving the Power Switch and the Ice Making Switch on the left of the Middle Front Panel to the ON position starts the automatic and continuous icemaking process When the Ice Storage Bin is filled with ice the Bin Control Switch will shut off the icemaking process As the ice is removed from the Storage Bin the Bin Control Switch resets automatically and restarts the icemaking process Moving the Ice Switch and the Water Switch located on the right of the Middle Front Panel to the ON and or OFF positions gives the user a convenient 3 way dispensing Ice Only ON OFF Water Only OFF ON Ice and Water ON ON The Agitator in the Storage Bin keeps t
32. h Lever or Push Button to dispense ice and remove all ice from the Storage Bin 3 off the power supply 4 Remove the Top Panel 5 Remove the Storage Bin Cover 6 Rotate the Agitator counterclockwise and lift off 7 Rotate the Drip Ring about 30 degrees clockwise and lift off 8 Install the new Drip Ring and Agitator 9 Assemble the removed parts in the reverse order of which they were removed 10 Turn on the power supply 11 Move the Ice Making Switch to the ON position IV 21 12 REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY 1 Move the Ice Making Switch to the OFF position 2 Press the Push Leveror Push Button to dispense ice and remove allice fromthe Storage Bin 3 Turn off the power supply 4 Remove the Drain Cap and drain out 5 Remove the panels 6 Remove the Storage Bin Assembly See 10 STORAGE BIN ASSEMBLY EXTRUDING HEAD 7 Lift off the Extruding Head 8 Replace the Bearing inside the Extruding Head if it is worn or scratched Note Replacing the Bearing needs a fitting tool If it is not available replace the whole Extruding Head AUGER 9 Lift up and turn the Auger until it comes off Ifthe areaincontact with the Bearing is worn out or the Blade scratched replace the Auger EVAPORATOR Note Skip the following steps 10 through 17 when the Evaporator does not need replacement 10 Recover the refrigerant and store itin an approved con
33. he Bin Liner and into the Reservoir through the opening in the center of the Storage Bin to melt the ice and rinse out the sanitizing solution Be careful not to wet the Bin Control Switch on the Storage Bin Cover 8 Immerse the parts rinsed in a step 19 into the sanitizing solution 9 Rinse the parts sanitized above using water 10 Replace the parts rinsed above in their correct position 11 Replace the Drain Cap in its correct position and open the Water Supply Line Shut off Valve 12 Move the Ice Making Switch to the ON position and start the icemaking process Run the ice dispenser for about 30 minutes 13 Move the Ice Making Switch to the OFF position 14 Press the Push Lever or Push Button to dispense ice and remove all ice from the Storage Bin 15 Remove the Drain Cap and drain out 16 Replace the Drain Cap in its correct position 17 Replace the Top Panel in its correct position 18 Move the Ice Making Switch to the ON position and start automatic and continuous icemaking process WATER VALVE IMPORTANT If the Filter in the Water Valve becomes clogged with sediment or dirt the water supply will be stopped and cannot be made Disassemble the Water Valve and clean out the Filter once every two months 1 Turn off the power supply 2 Close the Water Supply Line Shut off Valve and open the Drain Valve 3 Remove the panels 4 Remove the Fitting Nut from the Water Valve Do not l
34. he ice from clustering so that the ice can move easily through the Spout DCM 240BAA DCM 240BAB DCM 240BAE Ice Making Switch ICE Push Button SWITCH Indicator Lamp ice Switch Water Switch Power Switch Fuse Holder DCM 240BAB only HOLDER DCM9404 1 3 Z ENS aN 2 A 2 a HOSHIZAKI LET ICE DIS PE NS ER TE CHNI CAL x INFORMA TI ON DCM9404 CONTENTS PAGE 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 111 1 240 240 111 1 petente 11 2 olas III 3 DOM 240BAA Pet III 3 perugia 11 4 DOM 240BAE A T 111 5 3 SEQUENCE OF ELECTRICAL CIRCUIT i Q 1 6 4 PERFORMANCE DATA icon 11 34 240 PN 11 34 240 DA 111 35 240 21 5 9 1 11 36 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT DCM 240BAA DCM 240BAB WATER VALVE ICE MAKING STORAGE BIN gt gt FLOAT SWITCH 1 O E WATER III SUPPL _ spel RESERVOIR 7 7 2 EVAPORATOR 4 S N Ni EXPANSIO C gt lt dl WATER VALVE DISPENSE a Y DRAIN CAP GEAR MOTOR DRIER mi ACCESS VALVE COMPRESSOR ACCESS VALVE WATER CIRCUIT REFRIGERANT CIRCUIT Note The Access Valve
35. ing using a fitting tool if it is worn or scratched Note Replacing the Bearing needs a fitting tool If itis not available replace the whole Housing Be sure to install the O ring IV 23 GEAR MOTOR 24 Cut the Gear Motor leads at the wire connector 25 Remove the three Hexagon Bolts securing the Gear Motor on the Chassis 26 Remove the Gear Motor 27 Install the new Gear Motor 28 Assemble the removed parts in the reverse order of which they were removed WARNING Be careful not to scratch the surface of the O ring may cause water leaks Handle the Mechanical Seal with care not to scratch nor to contaminate its contact surface 29 Check for water leaks WARNING After assembling the Extruding Head be sure to check that the Auger does not contact with the inner surface of the Evaporator and there is not any abnormal noise from the Bearing 30 Turn on the power supply 31 Move the Ice Making Switch to the ON position DCM9404 IV 24 Z 4 J _ gt 2 HOSHIZAKI CUBELET ICE DISPENSER V MAINTENANCE AND CLEANING INSTRUCTIONS CONTENTS PAGE 1 PREPARING THE ICEMAKER FOR LONG STORAGE V 1 2 CLEANING INSTRUCTIONS a trente 3 a CLEANING PROCEDURE certet 3 0 SANITIZING PROCEDURE creto ttt V 5 WATER VALVE ccsccocccccecseccocsesoessveccusecucs
36. irt build up 2 Air Filter See Fig 7 A plastic mesh air filter removes dirt or dust from the air and keeps the Condenser from getting clogged Asthe filter gets clogged the ice dispenser s performance will be reduced Check the filter at least twice a month When clogged use warm water and a neutral cleaner to wash the filter 3 Condenser Check the Condenser once a year and clean if required by using a brush or vacuum cleaner Air Filter More frequent cleaning may be required depending onthe location of the ice dispenser Fig 7 V 8 Louver TOYOAKE AICHI JAPAN PHONE 0562 97 2111 TELEX NO 04486 514 HOSHI J
37. ll quality ice production capacity ice dispenser friction sound and Compressor heating conditions b SUCTION TEMPERATURE HOSHIZAKI s recommendation 1 Locate a Thermometer on the Evaporator Outlet Pipe at a point 2 4 away from the Evaporator Foam Insulation and check the Suction Pipe temperature 2 Adjust the Constant Pressure Expansion Valve so that the Thermometer can show the values indicated in Ill 4 PERFORMANCE DATA A frost line should be in front of the Compressor Inlet Pipe Note that this target is a center of temperature fluctuation IV 1 DCM9404 c SUCTION PRESSURE 1 Attach a pressure gauge to the Refrigerant Access Valve 2 Adjust the Constant Pressure Expansion Valve so that the pressure gauge shows the following value A frost line should be in front of the Compressor Inlet Pipe DCM 240BAA BAB Refrigerant 12 9 11 PSIG Note A 90 rotation of the Adjust Screw makes a 1 4 1 7 PSIG increase or decrease depending on directions CW to increase the low side pressure CCW to decrease the low side pressure High side CW CCW Adjust Screw Higher Lower Adjust Screw Cap Low side DCM9404 SERVICE DIAGNOSIS 1 NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE HEMEDY 1 The ice dispenser a Power Supply Cord 1 Check for continuity and will not start connection replace b Power Switch on left 1 OFF position 1 Move to ON position bottom of Front Panel Sw Except
38. m EXTERIOR FINISH Stainless Steel Painted Steel WEIGHT Net 141 lbs 64 kg Shipping 170 Ibs 77 CONNECTIONS ELECTRIC Cord Connection WATER SUPPLY Inlet 1 2 FPT DRAIN Outlet 3 4 MPT MAKING SYSTEM Auger type HARVESTING SYSTEM Direct driven Auger 80 W Gear Motor ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL N A BIN CONTROL SYSTEM Mechanical Bin Control Microswitch COMPRESSOR Hermetic 400 W Model CL50J 1U CONDENSER Air cooled Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Constant Pressure Expansion Valve REFRIGERANT CHARGE R12 8 8 oz 25 g DESIGN PRESSURE High 235 PSIG Low 140 PSIG COMPRESSOR PROTECTION Auto reset Overload Protector GEAR MOTOR PROTECTION Manual reset Circuit Breaker REFRIGERANT CIRCUIT PROTECTION N A LOW WATER PROTECTION Float Switch and Timer ACCESSORIES SUPPLIED Spare Fuse REQUIRED N A OPERATING CONDITIONS VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESS 10 113 PSIG We reserve the right to make changes in specifications and design without prior notice DCM9408 2 240 AC SUPPLY VOLTAGE 115 60 1 AMPERAGE C AT 104 80 MINIMUM CIRCUIT AMPACITY N A MAXIMUM FUSE SIZE N A Een APPROXIMATE ICE PRODUCTION abit ter Temp _ 0 9 210 122 230 104 230 104 200 90 180 82 165
39. move 7 Assemble the removed parts in the reverse order of which they were removed 8 Turn on the power supply and check that the Bin Control Switch works normally SNAP PIN 4 T d BALANCE RENTES A STORAGE BIN COVER BIN CONTROL INSIDE COVER SWITCH TOOTH E RING BALANCE PLATE B SHAFT DCM9404 IV 18 DCM9404 10 REMOVAL AND REPLACEMENT OF STORAGE BIN ASSEMBLY 1 Move the Ice Making Switch to the OFF position 2 Press the Push Lever or Push Button to dispense ice and remove all ice from the Storage Bin 3 Turn off the power supply 4 Remove the Drain Cap and drain out 5 Remove the panels 6 Remove the Storage Bin Cover 7 Remove the Agitator Drip Ring Drip Plate and Shutter Assembly 8 Remove the three Socket Head Cap Screws and lift off the Storage Bin Assembly 9 Install the new Storage Bin Assembly 10 Assemble the removed parts in the reverse order of which they were removed 11 Turn on the power supply 12 Move the Shutter to check for proper operation 13 Move the Ice Making Switch to the ON position IV 19 STORAGE BIN COVER AGITATOR STORAGE 40 SHUTTER EXTRUDING exo ASSEMBLY DRIP RING EVAPORATOR COVER STRAINER EVAPORATOR FREEZER SOCKET HEAD ASSEMBLY CAP SCREW DCM9404 IV 20 11 REMOVAL AND REPLACEMENT OF AGITATOR AND RING 1 Move the Ice Making Switch to the OFF position 2 Press the Pus
40. n blade caught on a foreign matter cylinder valve broken position other surfaces Making wear damage e Evaporator 1 Low side pressure too 1 Except DCM 240BAE low Adjust Expansion Valve Turn Adjust Screw CW See ADJUSTMENT OF COMPONENTS 1 CONSTANT PRESSURE EXPANSION VALVE 2 Scale on inside wall of Freezing Cylinder 1 Solenoid Shutter Plunger surface Plunger h Extruding Head i Housing REMOVAL AND REPLACEMENT OF COMPONENTS 1 SERVICE FOR REFRIGERANT LINE a REFRIGERANT RECOVERY This ice dispenser is provided with two Refrigerant Access Valves on the low side and high side lines Recover the refrigerant from these two Access Valves and store itin an approved container Do not discharge the refrigerant into the atmosphere b EVACUATION AND RECHARGE 1 Attach Charging Hoses a Service Manifold and a Vacuum Pump to the system 2 Turn on the Vacuum Pump 3 Allow the Vacuum Pump to pull down to a 29 9 Hg vacuum Evacuating period depends on pump capacity 4 Close the Low side Valve on the Service Manifold 5 Disconnect the Vacuum Pump and attach a Refrigerant Service Cylinder Remember to loosen the connection and purge the air from the Hose See the Nameplate for refrigerant charge Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No 700 88 be used 6 Open the Low side Valve Do not invert the Service Cylinder A liquid
41. ng process Run the ice dispenser until it stops automatically 14 Move the Ice Making Switch to the OFF position 15 Remove the Drain Cap and drain out 16 Pour clean warm water carefully onto the Bin Liner and into the Reservoir through the opening in the center of the Storage Bin to melt the ice and rinse out the cleaning solution 17 Replace the Drain Cap in its correct position 18 Wipe the Storage Bin Cover the Agitator the Drip Ring and the Sound Damper or Spout A and B using a clean cloth containing the cleaning solution 19 Rinse the parts wiped above using water CAUTION Do not use ice produced with cleaning and sanitizing solutions Be sure remains in the Storage Bin b SANITIZING PROCEDURE Following Cleaning Procedure 1 Dilute approximately 1 5 fl oz of a 5 25 Sodium Hypochlorite solution with 3 gal of water 2 Pourthe sanitizing solution carefully into the Reservoirthrough the opening in the center of the Storage Bin up to an overflow level 3 Wait for 10 minutes to start icemaking process Move the Ice Making Switch to the ON position and start automatic icemaking process Run the ice dispenser until it stops automatically 4 Move the Ice Making Switch to the OFF position V 5 DCM9404 5 Remove the Drain Cap and drain out 6 Wipe the Bin Liner and the Drip Plate using a clean cloth containing the sanitizing solution 7 Pour clean warm water carefully onto t
42. om the Storage Bin 6 Remove the Drain Cap and drain the Reservoir and Freezer 7 Replace the Drain Cap in its correct position 8 DCM 240BAA Remove the Sound Damper inside the Dispenser Nozzle See Fig 3 DCM 240BAB DCM 240BAE Remove the Spout A and B by removing the Thumbscrew sliding the Spouts backward and then pulling them down See Fig 4 Pull out the Spout A from the Spout B 9 Remove the Top Panel and Storage Bin Cover See Fig 5 DCM9404 V 3 DCM 240BAA DCM 240BAB DCM 240BAE Middle Front Panel ICE MAKING SWITCH Spout A Dispenser Nozzle Spout B Thumbscrew Dispenser Drain Cap Nozzle Sound Damper Fig 3 Fig 4 Bin Control Switch us Storage Bin Cover EZ A OCO o Shutter oe SEDET js 73 Agitator Drip Ring Ice Chute Drain Pipe 2 Extruding Head N N Insulation Auqer Fig 5 DCM9404 DCM9404 10 Remove the Agitator and Drip Ring See Fig 5 11 Pourthe cleaning solution carefully into the Reservoir through the opening in the center of the Storage Bin up to an overflow level Overflowed solution can be seen in the Drain Pan 12 While waiting for 10 minutes to start icemaking process wipe the Bin Liner and the Drip Plate using a clean cloth containing the cleaning solution 13 Move the Ice Making Switch to the ON position place the Storage Bin Cover in position and start automatic icemaki
43. ose the Packing 5 Remove the Filter from the Water Valve remove sediment or dirt and rinse it with water 6 Replace the Filter on the Water Valve 7 Replace the Packing and secure it carefully with the Fitting Nut to prevent leakage 8 Close the Water Supply Line Drain Valve and open the Shut off Valve 9 Turn on the power supply 10 Check for water leaks 11 Replace the panels in their correct position Valve Portion Diaphragm Filter Packing Fitting Nut DCM9404 V 7 DCM9404 3 MAINTENANCE IMPORTANT 1 This ice dispenser must be maintained individually referring to the instruction manual and labels provided with the ice dispenser 2 To have the optimum performance of this ice dispenser the following consumable parts need periodical inspection maintenance and replacement Extruding Head Housing Gear Motor Auger Mechanical Seal These parts should be inspected atleast once a year or every 10 000 hours of operation Their service life however depends on water quality and environment Morefrequentinspection and maintenance are recommended Consult with your local distributor about inspection and maintenance service Toobtainthe name and phone number of yourlocal distributor call Hoshizaki Care at 1 800 233 1940 1 Stainless Steel Exterior To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or d
44. s have been installed in the model DCM 240BAB from the Auxiliary Code B 3 DCM9404 1 240 WATER VALVE ICE MAKING STORAGE BIN FLOAT SWITCH c a TR WATER Iz RESERVOIR e 0 INLET W FREEZER D EVAPORATOR Nid E lg gt lt wl WATER VALVE H DISPENSE E I gt PRESSURE u GEAR MOTOR gt SWITCH MUFFLER pes DRIER CONDENSER mM ACCESS COMPRESSOR VALVE pru WATER CIRCUIT REFRIGERANT CIRCUIT DCM9404 B 2 2 WIRING DIAGRAM DCM 240BAA WIRE COLOR CODE 115 120 80 1 BK BLACK P PINK BK BR BROWN R RED LINE LINE DBU DARK BLUE Y VIOLET posa W WHITE POWER SWITCH FUSECISA NO BK BK LAMP P DISPENSING WATER SWITCH Suite 38 1 Ite 10 9 DISPENSING RELAY PROTECTOR UU TIMER FUSECIA 0 0 5 Sic PK 24Y O EN 1 826 30 NE EA WATER CONTROL LBU 65 111 _ An CONTROL E ICE BO MAKING I owe eR SWITCH FLOAT SWITCH DCM9404 _ 3 240 L N WIRE COLOR CODE M BR BROWN W WHITE POWER SWITCH 2 FUSE ISA go R RED ORANGE ge GY GRAY P PINK DBU DARK BLUE DISPENSING SWITCH 2 LBU LIGHT BLUE V VIOLET COM 70 P THERMAL gt PROTECTOR GEAR ae s PROTECT
45. t 60 sec after Gear Motor starts WIRE COLOR CODE 115 120 80 1 BK BLACK P PINK BK w BR BROWN RED E DBU DARK BLUE UNE LIN gen a SENSE Y POWER SWITCH FUSECSA BK LAMP T DISPENSING WATER SWITCH SWITCH ICE SWITCH d 5 3 10 0 DISPENSING 1 RELAY GEAR PROTECTOR Ma 1 LJ gt LJ ANA WATER CONTROL m ICE MAKING SWITCH 2 FLOAT SWITCH DCM 240BAA powssos MI 13 WIRE COLOR CODE BR BROWN W WHITE BK BLACK R RED O ORANGE GY GRAY PINK DBU DARK BLUE LBU LIGHT BLUE V VIOLET TIMER BOARD 111065 DCM9404 L ista L N BK POWER SWITCH ax FUSE ISA DISPENSING SWITCH gATER SWITCH WATER VALVE COM NO P ICE SWITCH LENOI y XU PN MOTOR 61 1 R PROTECTOR 20 6 9 5 9 a a i THERMAL PROTECTOR GEAR MOTOR 00 CAP T WATER VALVE BIN CONTROL SWITCH ICE MAKING SWITCH DCM 240BAB 14 WIRING DIAGRAM WIRE COLOR CODE BR BROWN Y WHITE BX BLACK R RED 0 ORANGE GY GRAY P PINK DBU DARK BLUE LBU LIGHT BLUE Y VIOLET TIMER BOARD 11106 5 gt N BK POWER SWITCH LANP aa d WATER SWITCH WATER VALVE JA ICE SWITCH SOLENOID MOTOR PROTECTOR E TERMAL SA gt m PROTECTOR L
46. tainer DCM9404 AUGER RING MECHANICAL SEAL EVAPORATOR O RING HOUSING IV 22 DCM9404 IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all otherrepairorreplacement has been made 11 Remove the Expansion Valve Cover 12 Remove the Insulation andthe two Clamps on the Expansion Valve Bulb DCM 240BAE only 13 Disconnect the brazing connections of the Expansion Valve and the Copper Tube Low Side from the Evaporator using brazing equipment 14 Braze the new Evaporator with nitrogen gas flowing at the pressure of 3 4 PSIG 15 Replace the Drier 16 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 17 Evacuate the system and charge it with refrigerant See the Nameplate forthe required refrigerant charge 18 Remove the four Socket Head Cap Screws at the bottom of the Evaporator 19 Disconnect the Hose from the Evaporator 20 Lift off the Evaporator HOUSING AND MECHANICAL SEAL 21 Remove the four Hexagon Bolts securing the Housing to the Gear Motor 22 Remove the Mechanical Seal fixed on the Housing Note The Mechanical Seal consists of two parts One moves along with the Auger and the otheris fixed on the Housing Ifthe contact surfaces of these two parts is worn or scratched the Mechanical Seal may cause water leaks and should be replaced 23 Replace the Bearing inside the Hous
47. ure bulb to low side Expansion Valve temperature exceeding line or replace DCM 240BAE the limit with refrigerant The amount of refrigerant is f Inside Wall of 1 Scale on inside wall of 1 Remove Auger Use Evaporator Freezing Cylinder LIME A WAY solution d Refrigerant Lines 1 Gas leaks 1 Check for leaks with a leak marked on Nameplate to clean periodically if water is found to surpass the following levels install a conditioner Hardness 50 ppm Silica 30 ppm Condenser blocking vents 3 Ambient temperature 3 Check ventilation and 2 Condensing temperature too high too high location and change as needed 4 Less than 6 clearance at rear sides and top ventilation DCM9404 3 FAULTY DISPENSER 1 No ice is a Storage Bin 1 Ice block or bridge 1 Remove all ice from dispensed Storage Bin when not b Agitator 1 Deformed due to ice block or bridge using ice dispenser for a 1 Coil winding opened 1 Replace long ti 1 Replace d Ice Switch or 1 Bad contacts 1 Check for continuity and Dispensing Switch replace e Ice Dispensing Relay 1 Bad contacts 1 Check for continuity and replace a Water Valve 1 Clogged Filter 1 Clean Dispensing 2 No water is m dispensed 2 Replace b Water Switch or 1 Bad contacts 1 Check for continuity and Dispensing Switch repl
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