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Hoshizaki DCM-500BWH-OS User's Manual

1. WIRING DIAGRAM WIRING DIAGRAM F 115 120760 4 16 0016 gt L N THERMAL N Ditto we GR PROTECTOR Qe m di e lt lt STARTER Ke STARTER G GND EE NE 0 2 RESISTOR RUN CAP RESISTOR RUN CAP MD i p BMF i ow a DU REIS START CAP START CAP 243 292MFD 243 292MFD ER ue wao fae 3 5b FAN MOTOR BR FAN MOTOR ONLY AIR COOLED BR ONLY AIR COOLED a S MODEL e Lgu MODEL w pe iedo m THERMAL THERMAL Yoyo OTR PROTECTOR DBU FUSE 20A qj 360 VAC V POWER SWITCH i zog DOOR SWITCH eH n j POWER PROTECT GEAR MOTOR GEAR MOTOR RAT PROTECT RELAY PONER PROTECT PROTECT RELAY Ls 51 3p 3 31 in P AGITATING MOTOR BK AGITATING MOTOR 8K ae DISPENSING ROTOR m ViSPENEN MOTOR s pan Gener 0 E a px iw NOSE KLLER RE IE LBU l TRANS FUSE A mim il NS 2 graph E R FUSE CA 2 E A DV LBU WATER OSPENSE wow BR nm eR DISPENSE al pad WATER VALVE 105V FUSE 5A BR eae DBU TOM NOSE KLLER RR gau Wig P IW LBU RASH DM no d FLUSH DRAN ZA LBU WATER VALVE peu 1 KE MAKING CO
2. LIGHT BLUE YELLOW 28 WIRING DIAGRAM WIRING DIAGRAM F 15 12076071 id 1 L N l THERMAL COMP THERMAI COMP m HE eth K ior PROTECTOR aK oe GND STATE GND T STARTER 9 w A NN B amp T BR 0 BR 0 f RESISTOR RUN CAP I l RESISTOR ANP l iy Tom 1 ow o jo y T p START CAP AMO 243 292MFD cien FEATER UE T B i fot 3 i MOTOR ONLY AIR COOLED BR FAN MOTOR p n AR COOLED i l wy MOL A ed C p THERMAL THERMAL PROTECTOR THERMAL PROTECTOR M PROTECTOR B Y 20 ES ERR DBU FUSE 20A 0 R E FUSE OO R 350 VAC W W V QN POWER SWITCH i POWER SWITCH m DOOR SWITCH all DOOR SwTCH iol d D GEAR MOTOR Danie POWER PROTECT ER OT it PROTECT RELAY 551 3 TS BR i aR 1 3 4 3 gs EH AGITATING MOTOR 0k AGTATING MOTOR BK T DBU DISPENSING MOTOR DBU DISPENSING MOTOR BR Cm BR Cm Lamas ae LBU NE eta isi NOISE KILLER i TRANS Oe QI w o R FUSE A gy W lag 181 R FUSE CA gy 24v BK pop DV WATER DISPENSE oy ns DISPENSE m DISPENSE
3. 18 ZW PERRA 20 1 Techmcal IMormatio eletti 21 A Water Circuit and Refrigeration Circuit sees 21 B Winng Diagrams tono oi IDA o etd irren E fero 29 1 DCM 500BAH DCM 500BWH antreten gna inest 23 2 DCM 500BAH OS DCM 500BWH OS 24 C Sequence of Electrical Circuit Ice Making eeecccceeeeeeeeeeeecceeeeeeeseneeeeeeeeeeeeaaeees 25 iM be mc a 25 2 lce P rge 26 3 Freeze YONG E 27 4 12 Hour Drain Cycle Drain Switch 28 2 TU HO WIPE a EREE 29 6 Low Water Safety C M 90 Higi Press re 91 D Sequence of Electrical Circuit Dispensing c ceceesesseseeeeeseeeeeeeeeeeeeeeeeeeeeeeeeess 32 T Got instet tor ord QUAD o ate cst Uud 32 2 Portion oli
4. WIRING DIAGRAM WIRING DIAGRAM 15 120 60 1 F 15 1207601 L QN L erp BS N Miiko OP R PTE for x oA d GND V STARTER NON 1 lI SS 5 BR 0 icula RESISTOR au cae l l RESISTOR CAP 1 DBU dl il 1 DBU n am START CAP ual START CAP 243 292MFD 243 292MFD EXER u HEATER B a E B MR FAN MOTOR roe ONLY AIR COOLED BR PA ONLY AIR COOLED igu MODEL BK iri THERMAL PROTECTOR THERMAL BRI Y op PROTECTOR ES 20 MFD DB FUSE BON 0 R 350 VAC Bu Wy W POWER SWITCH A 5 BK E s on SWITCH all Less POWER PROTECT GEAR MOTOR GEAR MOTOR BR RN RELAY FORT PROTECT RELAY T BIS LE d I m 3 Zorg ot ois AGITATING MOTOR BK AGTATNG MOTOR 8k DISPENSING NOTOR DBU DISPENSING MOTOR BR i SOLENOD ZAN BU FUEN O w 3 R gk 2 BK SINT LBU ER DISPENSE ERI DISPENSE SWITCH WATER VALVE DISPENSE ri WATER VALVE 105v FUSE 05A BR INO y CN o NOISE KILLER P yt WW F NOISE KILLER BH 8 LBU pau a ICE MAKING CONTROL Du t SWITCH aS IU NOSE KLLER MAKING CONTROLIT TF B SWITCH BK IROL LL LL4d Pal oe walle en NES VALVE zi S ES CONTROL NLET d B Lg l Or fo t 3 asalli BR VALVE K2 Kg LH l M OCM TER BOARD l BKI d B EIS 3 et FLOAT SWITCH id
5. THERMAL PROTECTOR STARTER BR 2 RESISTOR RUN CAP peu y START 243 292FD HEATER ONLY AIR COOLED M LBU FUSE 20A DBU 204 0 POWER SWITCH BK j DOOR SWITCH O POWER PROTECT GEAR MOTOR RELAY PROTECT RELAY EIS BR He 3 pH 31 AGITATING NOTOR BK DBU DISPENSING MOTOR BR SOLENOD 0 NOSE KILLER Lau TRANS o 0 R FUSE CA gy 2 8K M ov LBU DISPENSE oy WATER VALVE 105V FUSE 105A NM oS No NOSSE KILLER 1 BK BK p a B FLUSH DRAIN BU WATER VALVE n NOISE KILLER TE MAKING CONTROL j SWITCH za 8G i CONTROL INLET ir fo P 2315878351 32 1 WATER VALVE K i LH i NOISE KILLER DCM TIMER BOARD l in Control Board BK BK FLOAT SWITCH Ks RI BU T 234546 1 13439193 555 inii eu BK DBU HIGH PRESSURE i l NOISE KILLER SWITCH BR W PEE Bk eK R SENSOR 1 WIBR R U g eH WIBK gt T Ly W ee WIBU DISPENSE WO 2 7 SENSOR ns CONTROL WIR WR dS DISPENSE MODE Siren WIRE COLOR CODE Y D 0 d 0 ICE MAKING CONTROL BLACK a CONTROL SWITCH ICE MA sn BROWN E BLUE DARK BLUE LIGHT BLUE High Pressure Switch Air Cooled Model Water Cooled Model WHITE BLACK DARK BLUE ucer amp tue WHITEIBEACK Cut out 412x7 PSIG Cut in 327 21 PSIG 284 21 PSIG C Sequence of Electrical Circuit Ice Making
6. Auger Cylinder Evaporator Insulation Mechanical Seal O Ring Spline Coupling Gear UN Allen Head Cap Screw with Washer Housing and Lower Bearing Hex Head Bolt Rec ilb Washer 11 C Sequence of Operation N The steps in the sequence are as outlined below When power is supplied the power switch is in the ON position the door switch is engaged and the control switch is in the ICE position the POWER LED on the control board comes on Fill Cycle WV opens and the reservoir fills with water until UF S closes Note GM will not start unless UF S is closed For details see IV Service Diagnosis Ilce Purge Cycle 60 seconds GM LED is on WCR energizes closing the low water safety circuit and de energizing the WV GM and GMPR energize GM runs for 60 seconds to clear any ice from the evaporator Freeze Cycle GM LEDs are on C
7. RO 63 A Cleaning and Sanitizing Instructions o tex e Ot aue abe crie dues 63 DSTI T TUE 64 A 64 By Che gil O 64 C Sanitizing c E E 65 d Sanitizing Procedure Following Cleaning Procedure 65 2 Dispensing GampbfrTBrls a ceteris ez xd ERR ax bu CE RUM du 65 ciegas AE 65 5 Sanitizing ol Eom SUM 65 c Cleaning and Sanitizing 064116 65 B Maintenance OLESTIE 67 C Preparing the Icemaker for Long Storage esses 68 l Specifications A Icemaker 1 DCM 500BAH AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR AGITATING MOTOR DISPENSING MOTOR OTHERS MAXIMUM FUSE SIZE MAX HACR BREAKER USA ONLY MAX CIRC BREAKER CANADA ONLY MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY 115 60 1 120V 7 9 RLA 51 LRA 120 V 2 4 FLA 1 4 HP 120 V 1 0 FLA 50 W 120 V 0 9 FLA 55 W 120 V 0 9 FLA 55 W 120 V 0 2 A 20 A 20 A 20 A 20A WATER TEMP F CF 50 70 38 535 243 510 231 485 220 461 209 438 199 416 189 396 179 385
8. pue 1 5 OU WO4 Urep Jezijiues pue Jeueejo smo e Siu un eui Buizniues pue Buiuee o ueuM pesn s uoys oJjuoo eu uo uoiiisod NIVHO 24L uonisod NIVHG 901 U SI 0102 ay u ym pezibieu3 syueuoduio 9 UI AM 11109 HOM youms eoj 1eddn s 4n uo 3A 19561 LA 4nou ZL senunuoo U91IMS 180 5 31 fuo 3A 40 Aa senuguoo senuguoo ID feje1 99 14 1040W 1896 YANS Ajuo 3 Jo ui oz 3q uo Aa senuinuoo INS senumnuoo SINS Jojouu 1998 W9 Jo Jo Jo SINS senuinuoo dwog 419185 1 MOJ Jeuun II 11 pesop 9g Jo WD po dwog sues 9q 10 uedo 28 9 0qe 9 9 9 1 1 99S Od nou ZL p JOJOW UB peure1uoo Jies SINA UIP AG Jou Uep LA ejpfoumip g JosseJdujoo dwog ouo uiq 58 puoBe1 uejsaH uwopinus ueq ANOH ZL Sejnutui 06 40 uo AG 9 9 118106 9 0 eBung 99 5916111 UAA L spuooes 09 spuooes 06 x spuooes Qs 9 0qe 9 9 9 II L 995 9 97 89 y HO s 19 199 6 9 99 eBung a9 ny ulg L uejseu UMOPINYS Z senunuoo ydo Senunuoo Yd IND Senul uod INS Ssenunuoo W9 senunuoo AM senugnuoo SINA senumnuo SINS senunuoo YdIND senunuoo dwog senunuoo dwog uo
9. 33 E Performance Data eene eene nene mentre nnn rarr nanara nannan Ennen rre snae 34 1 DCM 500BAH QS adden ls UD em ede 34 2 DOM DSOOBVVEN CIS acute sete tt Mi tete RUE EU ona ERA uie eee rere ere 35 IV Service DIGNUS S E ere 96 A Diagnostic 96 B Ice a Check eee does 37 edP poculi giga TE DEO i LO DT 38 TENG ICS verenda nca eO acce pb i i RE 38 2 LOW Ice 41 TEIL E ETT 42 T 43 5 Opti Serve OS a SOS eaaet bacdt bred erento teins ee eee 44 V Removal and Replacement of Components 2 necis rara rasan aaa ai 46 A Service Tor Refrigerant LIS b eee casei odes 46 1T Heirigerant HecOVel V uoces KE a FIR xd aan cda d eu 46 2 eT M 46 3 Evacuation and Recharge 404 ieiiieke p hah kr ER TERRA TER Va 47 B Removal and Replacement of Compressor seessssssseeeeennenenen 48 C Removal and Replacement of Expansion 49 D Removal and Replacement of Evaporator Assembly Components 50 1 Upper Bearing Wear Check WT SET
10. Le ONTO FLOAT SWITCH 2 3818699 ere 3 uo F 6 _ B M eu 1 23458 1 34858183 m Lrr E EE Bl HIGH PRESSURE L DBU SWITCH NOISE KILLER HIGH PRESSURE d NOISE KILLER SWITCH WATER BR x aspense R SENSOR KE DISPENSE DISPENSE l SWITCH MODE E WiBR x R BK A 94 WIBK TOK NOT WATER CONTROL Y amp RELAY DSPENSE STE CONTA te es m WO SENSo MIS EMEN CN ul o DISPENSE NODE DEVE BON SW S7 E YANG CONTROLI BN CONTROL smrc C EE GY Gy LBU LBU WIRE COLOR CODE o ORANGE WBK WHITE BLACK BH BROWN P PINK WHITE BROWN BLUE R RED WHITE BLUE DARK BLUE VIOLET WHITE ORANGE GRAY WHITE WR WHITE RED LBU LIGHT BLUE YELLOW 26 3 Freeze Cycle Compressor and fan motor start 60 seconds after gear motor starts DCM 500BAH DCM 500BWH WIRING DIAGRAM 165 020 60 1 EX H ctor OP gy BK STARTER BR HEATER E E ONLY AR COOLED l wui MODEL E THERMAL ee PROTECTOR THERMAL GEAR NON py y PROTECTOR 9 20 MD BU FUSE 20A 9 R ens 30 VAC pc Em POWER SWITCH BK DOOR SWITCH p ili GEAR MOTOR REY PROTECT PROTECT RELAY BR io 4 3 25 AGTATING MOTOR DCM 500BAH OS DCM 500BWH OS WIRING DIAGRAM F 115 12076071 gt
11. 1 Refrigerant Recovery The icemaker is provided with refrigerant access valves Using proper refrigerant practices recover the refrigerant from the access valves and store it in an approved container Do not discharge the refrigerant into the atmosphere 2 Brazing WARNING 1 R 4044 itself is not flammable at atmospheric pressure and temperatures up 2 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 3 Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere 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 46 1 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 2 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 3 Use an electronic leak det
12. Em with Washer rA b Housing and o Lower Bearing N gt T i i Spline Coupling Fig 1 Gear T cii 50 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 2 1 Move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 2 Remove the front cover of the storage bin Remove spout B then remove spout A and the cutter See Fig 1 02 Round Stock or Pin Gauge 3 Grasp the top of the auger and move the auger towards you and then try to insert a 02 round stock or pin gauge in between the back side of the auger shaft and the bearing surface Check several locations around the auger shaft If the gauge goes between the shaft and the bearing at any point or if the bearing is scratched or cracked both the top bearing MN in the extruding head and the lower NO bearing in the housing should be replaced Instructions for removing the extruding Fig 2 head and housing are located later in this procedure Note Replacing the bearing requires a bearing press adaptor If one is not available replace the whole extruding head and housing 4 Replace the cutter spout A spout B and the front cover of the storage bin in their correct positions 5 Move the power switch to the ON po
13. e o t E t RN BEY PROIECTOR ou FUSE 208 R 550 VAC BU FUSE 204 0 m upci 350 VAC z W W POWER SWITCH n POWER SWITCH K E EN a ret ret DOOR SWITCH ial Lew pooR SWITCH ilex POWER PROTECT GEAR MOTOR c GEAR MOTOR reli PE PROTECT RELAY REA eT PROTECT RELAY EUIS p m ears SETA Tic Ts 1 pss 3 1 AGITATING MOTOR Bk AGITATING MOTOR 8 DISPENSING MOTOR m DSFENSNG MOTOR 88 T i S LBU NOSE KILLER i IW TRANS FUSE 1A 40 eam oll B FUSE 1A Bk An ov LBU i 105V WATER DISPENSE BR SE Sh DISPENSE DSE swo WATER Vave aue os mme fe T NOI Du a NOSE KILLER mg rg B IFW FLUSH ORAM WATER VALVE 1BU WATER VANE KE MAKING CONTROL DBU Sw Ne NE AUER L MNA NOISE KILLER E H TE TERIS CONTROL a 1 iL 1 2345678 3 BR WATER VALVE 4 3 di 4 CONTROL NLET E m f 2325678 33 1 i BR NOSE KLLER kt K2 a NOISE KILLER 2 KER Eni Bowe x2 OO TIER BOND gio i M FLOAT NIU FLOAT SWITCH opoo 6 ao gt ou 1 Hd 1234331193 HIGH PRESSURE E J E 2 n L SWITCH HIGH PRESSURE d NOSE KLLER SWITCH WATER KW r BR ep x oer 0 KE DISPENSE DISPENSE L v SS rs H SWITCH BK M T Li CEF W BK Cl WATER CONTROL Hox ERU RELAY DISPENSE WATER CONTROL La ik ap SENSOR WATE at LRQ 6 DISPENSE MODE B
14. BK ra Br on SWITCH 1 n GEAR MOTOR POWER PROTECT PROTECT RELAY SIT BR rik iun 4 3 AE BK AGITATING MOTO DBU DISPENSING NOTOR SOLENOI 0 LBU TRANS FUSE 1h S 7 R K 248 uU LBU eger qr WATER DISPENSE 05V FUSE OSA fer DISPENSE SWITCH WATER VALVE an DBU Genk TOM rem I NOSE KLLER T P BK FLUSH ORAN WATER VALVE MAKING CONTROL fe DBU SWITCH NOISE KILLER BREER C Ci No fF PRS CTE 12 t Kt K2 2 Lig I OSE KILLER l a DCM TIER BOARD BKI Control Board FLOAT SWITCH RI cos d BU Ki ae HIGH PRESSURE Bu SWITCH OISE KILLER E b Krt Y gars am c WIRE COLOR CODE Iles BK A LAA low BK TON WATER CONTROL ww FLAY V CN 0 0 ae BN CONTROL SWITCH 7 KE MAKING CONTROL Gy SWITCH LBU High Pressure Switch Air Cooled Model 412 PSIG 327221 PSIG 2 DCM 500BAH OS DCM 500BWH OS WIRING DIAGRAM 415 120 60 1
15. 1 Fill Cycle With the power switch in the ON position and the control switch in the ICE position the inlet water valve energizes and the reservoir fills with water until the upper float switch closes DCM 500BAH DCM 500BWH DCM 500BAH OS DCM 500BWH OS WIRING DIAGRAM WIRING DIAGRAM F 415 12076071 F 15 0080 J L N L THERMAL COMP THERM WP m CO qi PROTECTOR GND GND 2 BR BR D RESISTOR i RESISTOR Bu PT el Tr ae START CAP STRT GAP 243 292MFD ENR o eoo HEMER ue J
16. 175 358 162 100 340 154 323 147 304 138 Cubelet Compressed Flake Ice Apprx 90 Ice 90 70 F CONDUCTIVITY 200 us cm 40 Ibs ELECTRIC amp WATER CONSUMPTION 90 70 F 70 50 F ELECTRIC W kWH 100 lbs 1055 6 6 985 4 4 POTABLE WATER 46 11 9 64 11 9 al 24HR__ gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN ICE MAKING SYSTEM HARVESTING SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION GEAR MOTOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 26 x 22 1 2 x 40 661 x 571 x 1016 mm Stainless Steel Galvanized Steel Rear NET 251 Ibs 114 kg Shipping 276 Ibs 125 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT x2 Auger type Direct Driven Auger 1 4 HP Gear Motor Float Switch N A Mechanical Bin Control Proximity Sw Hermetic Model RS43C2E CAA 219 Air cooled Fin and tube type Copper Tube on Cylinder Thermostatic Expansion Valve R404A 1 Ib 4 1 oz 570g High 460 PSIG Low 290 PSIG High Voltage Cut out Relay Auto reset Overload Protector Auto reset Thermal Protector Fuse Auto reset High Pressure Control Switch Float Switch and Timer Spare Fuse
17. Condenser Access Access mpressor Valve Compress Valve Refrigeration Circuit EE Water Circuit 21 2 DCM 500BWH OS Inlet Spout Water Valve Water Supply jjo Float Switch m Water Level Reservoir Evaporator Overflow Expansion Valve is To Drain Drain Valve Gear Motor fo Dispensing Water Valve Water Supply In Water Cooled Condenser High Pressure Switch m Water Supply Out LJ Water Regulating Valve Access Valve Compressor Refrigeration Circuit Water Circuit 22 B Wiring Diagrams 1 DCM 500BAH DCM 500BWH WIRING DIAGRAM 115 1206071 L HERMA Og 63 0 STARTE Qe v GND GN 6 BR pee RESISTOR CAP T MED ow START CAP 24 20 AW HEATER CAP p ONLY AIR COOLED Leu MODEL THERMAL TM 99 of DBU FUSE CON p R 350 VAC W W 7 POWER SWITCH
18. 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 the right and left side panels Next remove the rear panel 4 Prepare a container to catch water from the reservoir and evaporator then disconnect the hose from the drain valve and allow all of the water from the reservoir and evaporator to drain into the container 5 Disconnect the wire terminals from the drain valve 6 Remove the drain valve bracket 7 Remove the old drain valve and install the new drain valve 8 Replace the drain valve bracket in its correct position 9 Reconnect the wires and hoses 60 10 Open the water supply line shut off valve 11 Turn on the power supply move the power switch to the ON position then replace the front panel in its correct position to engage the door switch Move the control switch to the ICE position 12 13 14 15 Allow the icemaker to fill for two minutes Move the control switch to the OFF position Remove the front panel and check for water leaks wae a fT Move the control switch to the DRAIN position Engage the door switch and make sure that water is draining and that there are no water leaks around the hose connection 16 Move the control switch to the OFF position and disengage the door switch 17 Replace the panels in their correct positions 1
19. 2 Bad contacts 2 Check for continuity and replace i Water Control Relay 1 Bad contacts 1 Check for continuity and replace 2 Coil winding open 2 Replace j Inlet Water Valve 1 Mesh filter or orifice 1 Clean clogged 2 Coil winding open 2 Replace 3 Wiring to inlet water 3 Check for loose or open valve connection Repair or replace k Float Switch 1 Bad contacts 1 Check for continuity and replace 2 Float does not move 2 Clean or replace freely l Bin Control 1 Bin full check for continuity on proximity switch 2 Actuator sticking 2 Adjust or replace 3 Proximity switch open 3 Replace 38 Possible Cause 1 The icemaker will m High Pressure Switch 1 Bad contacts 1 Check for continuity and not start Fill Cycle replace continued 2 Dirty air filter or 2 Clean condenser 3 Ambient or condenser 3 Reduce temperature water temperature too warm 4 Refrigerant 4 Recover evacuate and overcharged recharge 5 Fan not operating 5 See 3 2 a Fan Motor except water cooled model 6 Refrigerant line or 6 Remove the restriction or components restricted component and replace the drier 7 Condenser water 7 Check and get pressure too low or off recommended pressure water cooled model only 8 Water regulating 8 Adjust it lower valve set too high water cooled model only y n Plug and Receptacle 1 Disconnected Cont
20. Co ow GND Gyo 5 SI 12 3 m 0 i j l I RESISTOR pe A RESISTOR RUN CAB Io w V I li t DR pa il coal cr START CAP iis EM EATER mE EATER om FAN MOTOR T BR FAN MOTOR ONLY AR COOLED BR ONLY AIR COOLED Ea MODEL 3 1 tay ODEL RNa 180 y um POEL tor THERMAL z M em y QUE CTR NRY PROTECTOR DBU FUSE 204 p 550 VAC DBU FUSE 200 0 RA oT 350 VAC W POWER SWITCH POWER SWITCH i LIS 8 BK zd nm K l z on SWITCH ie Les DOOR SwiTCH irl less p M Ee POWER PROTECT GEAR MOTOR GEAR MOTOR RT us PROTECT RELAY Peg TRE PROTECT RELAY 8 5T 8 7 i MEE ans 3 Eri AGITATING MOTOR Ed AGTATNG MOTOR BK oe eS ui DBU DISPENSING MOTOR DBU DISPENSING MOTOR BR i d LLER LBU NOSE KILLER Lau IW 5 o TRANS D eO FUSE 14 R 2 K n 15 R FUSE IA gk 249 8K aw ov LBU WATER DISPENSE FUSE OSA sn en vu DISPENSE DISPENSE up pni WATER VALVE FUSE 05A BR ou INO BU KILLER NOISE KILLER ga rg P IFAW i LBU FLUSH DRAN BK BK WATER VALVE wu MATER TANE ICE MAKING CONTROL DBU SWITCH 7 NOISE KILLER DBU NOISE KLLER i TE MAKING CONTROL _ il _ qw gt Wg SWITCH i mM m ONTROL 7 E j T T QNO 2315618 33 1 BR ALVI d ic CONTROL INLETI 3 5 i ILC Or fo P 33256768 3 1 BR WATER VALVE um x i Sos l OSE KLLER n m DCM TER BOA
21. SWITCH WATER VALVE i WATER VALVE 105V FUSE 05A DBU disi om Hr s 5 am NOISE KILLER NOISE KILLER gangs IE 42 Hour Drain Cycle BJ FLUSH ORANI 1 LU Bo FLUSTORENT WATER VALVE 12 Hour Drain Cycle Manual Drain Cycle DBU E AKNG Lem Manual Drain Cycle DBU BW TE MAKING CONTROL E E L Jw l mK EC Std Soi Mg 3 m CONTROL NLET S a spe Fd Pd A CONTROL NLET 2315818 32 3 l CAP MER WE Nc d No 55222828585 1 l BR WATER VALVE a 5 s r 6 Le NOSE KILLER K2 3 l d KILLER 2 oy ve ono gat e x pial go gg u FLOAT SWITCH a P FLOAT SWITCH eu ee eee ee e ore i Tass 1 1345987383 ere ES c 13 L ES 8K Uu T z 3 8 HIGH PRESSURE rt z SWITCH NOISE KILLER HG PRESSURE NOISE KILLER 5 BR oTo K roig BR 8k gg ti BK Y h NT 31 ep SENSOR _ KE DISPENSE DISPENSE i Sb Y SWITCH ME Dl le R Z7 gon aK ma le E iral Nnm Y KE 1 TOR JN l WATER CONTROL wau W SPENSE a RELAY wo SENSOR WATER CONTROL Lah oe WR LR RELAY DISPENSE MODE 0 amp A 9 BN CONTROL switch P CONTROL BIN CONTROL SWITCH KE MAKING CONTROL iv SWITCH GY LBU LBU WIRE COLOR CODE BLACK o ORANGE W BK WHITE BLACK BR BROWN P PINK WBR WHITE BROWN BLUE R RED WBU TWHITE BLUE DARK BLUE VIOLET WHITE ORANGE GRAY WHITE WHITE RED 5 Shutdown The bin control switch is a
22. is 60 seconds After 60 seconds the dispense switch must be disengaged and engaged again DCM 500BAH DCM 500BAH OS DCM 500BWH DCM 500BWH OS WIRING DIAGRAM WIRING DIAGRAM 115 020 60 1 F 415 120 60 1 1 1 d De p R BK GND OR gt A BK Qe STARTER STARTER ty W GND A fy 5 3R t 4 7 RESISTOR RUN CAP RESISTOR Im pn pA T9 4 DBU 243 292MF 0 243 292MFD nm CES EE uS HEATER HEATER pe om So ONLY AIR COOLED BR FAN MOTOR ONLY AR COOLED R TANM mr w tay BN eel ed Bits THERMAL N GEAR PROTECTOR Y zo wep T DBU FUSE 20A v 80 350 VAC W W 0 LBU POWER SWITCH fp HERMAL PROTECTOR T BK Iz LI i SWITCH all lle Le
23. line of the system 2 Five minutes after a freeze cycle starts Adjustment Screw confirm that the thermometer reads 104 F to 115 F 40 C to 46 C If it does not rotate the adjustment screw by using a flat blade screwdriver until the temperature Top View is in the proper range See Fig 4 Next check that the reference pressure is in the range indicated in the Head Pressure table in the Performance Data section If it is not Fig 4 in the proper range verify the refrigerant charge CW Higher CCW Lower 3 Check that the condenser drain temperature is stable I Removal and Replacement of Fan Motor 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 apron panel 3 Disconnect the wire connectors from the fan motor leads 4 Remove the fan motor bracket 5 Remove the fan blade and install it onto the new fan motor 6 Install the new fan motor onto the fan motor bracket 7 Replace the fan motor bracket in its correct position and reconnect the wire connectors 8 Move the power switch to the ON position then replace the panels in their correct positions 9 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 59 J Removal and Replacement of Inlet or Dispensing Water Valve 1 Close the water supply
24. line shut off valve 2 Open the water supply line drain valve 3 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 4 Remove the apron panel For the inlet water valve remove the left side panel For the dispensing water valve remove the right side panel 5 Disconnect the wire terminals from the water valve 6 Loosen the fitting nut on the water valve Do not lose the washer inside the fitting nut 7 Remove the water valve bracket inlet water valve or water valve dispensing water valve 8 Remove the old water valve and install the new water valve Remove the supply hose from the old water valve and place on the new water valve 9 Replace the water valve bracket inlet water valve or water valve dispensing water valve in its correct position 10 Reconnect the wire terminals 11 Reconnect the fitting nut on the water valve Make sure the washer is in place in the fitting nut 12 Close the water supply line drain valve and open the water supply line shut off valve 13 Check for water leaks 14 Move the power switch to the ON position then replace the panels in their correct positions 15 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process K Removal and Replacement of Drain Valve 1 Close the water supply line shut off valve 2
25. 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 N No Nuo Replace spout A spout B and the front cover of the storage bin in their correct positions 54 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 6 Removal and Replacement of Gear Motor 1 Move the control switch to the DRAIN position and drain all of the water from the evaporator 2 After the water has stopped draining move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 3 Remove the front cover of the storage bin Remove spout B then remove spout A See Fig 1 4 Remove the apron panel then remove the left side panel 5 Remove the evaporator bracket 6 R
26. should be closed Check the low water safety circuit on the water control relay terminals 4 and 6 check for 115 120V at the K1 connector COM terminal to neutral and NO terminal to neutral on the control board see wiring diagram check the gear motor fuse overload protector thermal protector gear motor capacitor and motor windings If the gear motor starts but the auger does not turn check the gear motor coupling between the auger and the gear motor If the compressor starts at the same time the gear motor starts check the X2 compressor relay on the control board 5 Freeze Cycle GM COMP LED are on The compressor and fan motor energize the gear motor protect relay gear motor and water control relay remain energized Ice production begins 4 to 6 minutes after the compressor and fan motor start depending on ambient and water temperature conditions Diagnosis Check that the compressor and fan motor are running If not check for voltage on and to the compressor X2 relay on the control board Check that the gear motor protect relay circuit terminals 3 and 5 are closed check the compressor internal overload thermal protector the compressor capacitors fan capacitor and voltage to the fan motor 36 6 Refill Low Water Safety As ice is produced the water level in the reservoir drops As the water level drops the upper and lower float switches open First the upper float switch opens Nothing occurs at this time W
27. the float switch Scale on the switch can cause the floats to stick In this case the float switch should be cleaned and checked First remove the switch from the water tank Soak the switch assembly in ice machine cleaner 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 Installing the floats upside down will affect the timing of the float switch operation Once clean rinse and wipe the cleaner off Next check the switch with an ohm meter This float switch has three wires the black wire is common and two separate switches Check the upper switch by ohming out the black and red wires When the float is up the switch should be closed Check the lower switch by ohming out the black and blue wires in the same manner If either switch fails the assembly should be replaced Red upper Black common Blue lower fed Q D a O t o Oo 2 Lower Float white Plastic Retainer Clip 20 Ill Technical Information A Water Circuit and Refrigeration Circuit 1 DCM 500BAH OS Inlet Spout Water Valve Tate DPN 15 Float Switch Wess Water Level Reservoir Overflow Expansion Valve is To Drain Gear Motor Valve 5 Dispensing Water Valve High Pressure Switch Air Cooled
28. to make changes in specifications and design without prior notice 34 2 DCM 500BWH OS APPROXIMATE ICE PRODUCTION PER 24 HR 70 80 90 Ibs day l day 100 APPROXIMATE ELECTRIC 70 CONSUMPTION 80 90 100 APPROXIMATE WATER 70 CONSUMPTION PER 24 HR 80 90 kl day 100 EVAPORATOR OUTLET TEMP 70 F C 80 90 100 HEAD PRESSURE 70 80 90 PSIG kg cm G 100 SUCTION PRESSURE 70 PSIG kg cm G 80 90 100 Ambient WATER FLOW FOR CONDENSER PRESSURE DROP OF COOLING WATER LINE HEAT OF REJECTION FROM CONDENSER HEAT OF REJECTION FROM COMPRESSOR Note Temp F 8 70 o 21 gal h AT 90 F WT 70 F Less than 7 PSIG 5438 BTU h AT 90 F WT 70 F 1104 BTU h AT 90 F WT 70 F 1 The data without marks should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 35 IV Service Diagnosis A Diagnostic Procedure This diagnostic procedure is a sequence check that allows you to diagnose the electrical system and components Before proceeding check for correct installation adequate water supply minimum of 10 PSIG maximum of 113 PSIG and proper voltage per unit nameplate Always choose a white neutral wire to establish a good neutral connection when checking voltages LEDs on the control board correspond to the components as they energize 1 Move the control switch to the OFF position then turn off the power supply Re
29. when sliding back the motor See Fig 5 4 Remove the thumbscrews from the horizontal plane of the motor bracket 5 Remove the motor from the bracket 61 6 Install the new motor 7 Assemble the removed parts in the reverse order of which they were removed 8 Move the power switch to the ON position then replace the panels in their correct positions 9 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process Agitator Agitating Motor Dispensing Motor Dispensing Auger Fig 5 62 VI Cleaning and Maintenance IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any cleaning or maintenance is done to the equipment A Cleaning and Sanitizing Instructions HOSHIZAKI recommends cleaning this unit at least twice a year More frequent cleaning however may be required in some existing water conditions WARNING 1 To prevent injury to individuals do not use any ammonia type cleaners 2 Carefully follow any instructions provided with the bottles of cleaning and sanitizing solution 3 Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin 4 After cleaning do not use ice made from the cleaning and sanitizing solutions Be careful not to leave any solution on the parts or in the storage bin Evaporator Assembly Reservoir Po
30. 385 175 358 162 340 154 323 147 304 138 Cubelet Compressed Flake Ice Apprx 90 Ice 90 70 F CONDUCTIVITY 200 us cm 40 Ibs 90 70 F 70 50 F 1055 6 6 985 4 4 46 11 9 64 11 9 26 x 22 1 2 x 40 661x571 x 1016 mm Stainless Steel Galvanized Steel Rear NET 251 Ibs 114 kg Shipping 276 Ibs 125 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 x2 Auger type Direct Driven Auger 1 6 HP Gear Motor Float Switch N A Photoelectric Sensor Infrared Mechanical Bin Control Proximity Sw Hermetic Model RS43C2E CAA 219 Air cooled Fin and tube type Copper Tube on Cylinder Thermostatic Expansion Valve R404A 1 Ib 4 1 oz 570g High 460 PSIG Low 290 PSIG High Voltage Cut out Relay Auto reset Overload Protector Auto reset Thermal Protector Fuse Auto reset High Pressure Control Switch Float Switch and Timer Spare Fuse Legs VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 6 3 DCM 500BWH AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR AGITATING MOTOR DISPENSING MOTOR OTHERS MAXIMUM FUSE SIZE MAX HACR BREAKER USA ONLY MAX CIRC BREAKER CANADA ONLY MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE QUALITY APPROXIMATE
31. 51 2 Removal and Replacement Extruding Head ssss 51 3 Removal and Replacement of Auger iiusssassakannk at ct ctor vrbe bx hietdg mak XA RA NEU REG 52 4 Removal and Replacement of pupa Ra S Exo vk FX cnr ppc nene 52 5 Removal and Replacement of Mechanical Seal and Lower Housing 54 6 Removal and Replacement of Gear Motor c ccccscscceeeeeeeeeeeeeeeeeeeeseeeeeeess 55 E Removal and Replacement of Self Contained Air Cooled Condenser 56 F Removal and Replacement of Water Cooled 57 G Removal and Replacement of Water Regulating Valve Water Cooled Model Only 58 H Adjustment of Water Regulating Valve Water Cooled Model Only 59 Il Removal and Replacement of Fan Motor eere reno rne 59 J Removal and Replacement of Inlet or Dispensing Water Valve 60 K Removal and Replacement of Drain Valv6 ciiin exar n urn nni nnnm nn inania 60 L Removal and Replacement of Dispensing 61 1 Dispensing Auger and Adlt tOr uuiia c adea Ra tod ra ew Fr Ei dni HR RD 61 2 DISPENSING r Agitating Motor obrem ded d ewe Eccc 61 n icle me
32. 8 Move the control switch to the ICE position to start the automatic ice making process L Removal and Replacement of Dispensing System 1 Dispensing Auger and Agitator 1 Move the control switch to the OFF position then turn off the power supply Remove the front and top panels then move the power switch to the OFF position 2 Remove the front cover of the storage bin 3 Remove the thumbscrews from the vertical plane then loosen the thumbscrews from the horizontal plane of the motor bracket Slide the motor back Note Hold the dispensing auger agitator to prevent it from dropping when sliding back the motor See Fig 5 4 Replace the dispensing auger agitator with the new one 5 Assemble the removed parts in the reverse order of which they were removed 6 Move the power switch to the ON position then replace the panels in their correct positions 7 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 2 Dispensing or Agitating Motor 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 storage bin front panel 3 Remove the thumbscrews from the vertical plane then loosen the thumbscrews from the horizontal plane of the motor bracket Slide the motor back Note Hold the dispensing auger agitator to prevent it from dropping
33. C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION GEAR MOTOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 115 60 1 120 V 7 9RLA 51 LRA 120 V 1 6 FLA 1 6 HP 120 V 0 9 FLA 55 W 120 V 0 9FLA 55 W 120 V 0 2A 20A 20A WATER TEMP F CF 50 70 90 Cubelet Compressed Flake Ice Approx 89 Ice 90 70 F CONDUCTIVITY 200 us cm 40 Ibs 90 70 F 70 50 F 930 4 8 985 4 0 56 12 65 12 465 100 285 52 26 x 22 1 2 x 40 661 x 571 x 1016 mm Stainless Steel Galvanized Steel Rear Net 245 Ibs 111 kg Shipping 269 Ibs 122 kg Permanent Connection Inlet 1 2 FPT Condenser Inlet 1 2 FPT Outlet 3 4 FPT x2 Condenser Outlet 3 8 FPT Auger type Direct Driven Auger 1 6 HP Gear Motor Float Switch Automatic Water Regulator Photoelectric Sensor Infrared Mechanical Bin Control Proximity Sw Hermetic Model RS43C2bE CAA 219 Water Cooled Double Tube Type Copper Tube on Cylinder Thermostatic Expansion Valve R404A 14 1 oz 400g High 460 PSIG Low 290 PSIG High Voltage Cut out Relay Auto reset Overload Protector Auto reset Thermal Protector Fuse Auto reset High Pressure Control Switch Float Switch and Timer Spare Fuse Legs VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and desi
34. HdIND senuinuoo YdIND senumnuoo W9 Jo AM uo AM senunuco YdIND uo INS 5950 9 S 4N senumnuoo W9 senunuoo SINA 09506 uo 14 985 06 peueis 14 senunuoo W9 AM iun senuguoo AM senuguoo0 AM Senunuoo dwog uo HOM Jo HOM senunuoo YOM uo H9M gt yo Yd ND yo SINA pepeeoxe 14 jo AM pasojo 5 4 UO AM uedo 6 31 uo SW4 40 AM pasoi S N uedo s 4n IND yo dwog uedo s 4n pesojp 41 uedo s 4n uo dwog pesoj 9 31 spuooes 06 4 spuoves 06 eouenbes uwopinus 995 OSL Y Wed spuooes 09 spuooes 09 3Ol Ul YOUMS AX 4NO U9IIMS 190g dnyeis suiBeq eouenbes uwopinus puooes OG L4 998 06 lt II JI Ayayes 191e AA MO1 9 9 9 929911 9 m Wo 8q ure1q 1 61 9 995 sinoy Z sejnuiu 40 suedo 8 99 11811 NOH 9 0 eBung 29 Z 11 7L uoneJedo 1ueuoduio pue 9 eouenbes SO HM amp 8009 INOG SO HV amp 800S INOG 13 D Control Board A Hoshizaki exclusive solid state control board is employed in DCM 500BAH DCM 500BAH OS DCM 500BWH and DCM 500BWH OS Cubelet Icemaker Dispensers All models are pretested and factory adjusted CAUTION 1 Fragile handle very carefully 2 The control board contains integrated circuits which are susceptible to failure due to sta
35. Hoshizaki America Inc Cubelet Icemaker Dispenser Models DCM 500BAH DCM 500BAH OS DCM 500BWH DCM 500BWH OS SERVICE MANUAL A Superior Degree of Reliability www hoshizaki com Number 73165 Issued 7 30 2008 IMPORTANT Only qualified service technicians should attempt to install service or maintain this icemaker No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual Failure to service and maintain the equipment in accordance with this manual may adversely affect safety performance and warranty coverage 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 write or send an e mail message to the Hoshizaki Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn Hoshizaki Technical Support Department Phone 1 800 233 1940 Technical Service 770 487 2331 Fax 1 800 843 1056 770 487 3360 E mail techsupport 9 hoshizaki com 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 ca
36. ITE BLACK BR BROWN P PINK W BR WHITE BROWN BLUE R RED WBU WHITE BLUE DARK BLUE VIOLET WHITE ORANGE GRAY WHITE WHITE RED LIGHT BLUE YELLOW 32 2 Portion Dispense Agitating motor energizes for 6 seconds for every 12 seconds of accumulative dispense time A variable resistor which controls the amount of ice dispensed is located on the control board The figures on the label indicate dispensing time sec See Il D 3 a Portion Control When shipped the portion control is set at the minimum dispensing time 0 6 sec DCM 500BAH OS DCM 500BWH OS Approximately 0 72 oz lt Amount of ice dispensed per second DCM 500BAH OS DCM 500BWH OS Approximately 1 2 oz 8 DISPTIME 20 DCM 500BAH DCM 500BAH OS DCM 500BWH DCM 500BWH OS
37. Legs VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 2 DCM 500BAH OS AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR FAN MOTOR AGITATING MOTOR DISPENSING MOTOR OTHERS MAXIMUM FUSE SIZE MAX HACR BREAKER USA ONLY MAX CIRC BREAKER CANADA ONLY MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 Ibs POTABLE WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN ICE MAKING SYSTEM HARVESTING SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL DISPENSER CONTROL SYSTEM BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION GEAR MOTOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 115 60 1 120 V 7 9 RLA 51 LRA 120 V 1 6 FLA 1 6 HP 120 V 0 6 FLA 30 W 120 V 0 9 FLA 55W 120V 0 9 FLA 55W 120V 0 2A 20A 20A 20A WATER TEMP F JU 59 70 90 525 238 510 231 485 220 461 209 438 199 416 189 396 179
38. MODE BK Y Y y E TON M BUT o E WATER CONTROL lcm ex 4 WIR R L RELAY P ore DISPENSE MODE E Lm i ay MAKING NR BN CONTROL SW S 7 EE AKNG CONTROL SNTE SWITCH Gt LBU LBU WIRE COLOR CODE BK BLACK o ORANGE WHITE BLACK BR BROWN P PNK WHITE BROWN BLUE R RED WHITE BLUE DARK BLUE e VIOLET WHITE ORANGE GRAY WHITE WHITE RED LIGHT BLUE YELLOW 27 4 12 Hour Drain Cycle Drain Switch 12 hour timer initiates cycle or the control switch is moved to the DRAIN position 90 seconds after initiation the compressor and condenser fan motor stop 60 seconds later the gear motor stops Once the gear motor protect relay de energizes the drain water valve opens In the 12 hour drain cycle the drain water valve remains open for 20 minutes When the drain cycle is initiated manually using the control switch the drain valve remains open until the control switch is moved to the ICE position DCM 500BAH DCM 500BWH DCM 500BAH OS DCM 500BWH OS
39. N CONTROL SWITCH 65 KE MAKING CONTROL BIN CONTROL SWITCH TE ANG CONTROL a SWITCH a n LBU WIRE COLOR CODE BK BLACK o ORANGE W BK WHITE BLACK BR BROWN P PINK W BR WHITE BROWN BLUE R RED WBU WHITE BLUE DARK BLUE VIOLET WHITE ORANGE GRAY WHITE WHITE RED LIGHT BLUE YELLOW 6 Low Water Safety Upper float switch fails to close within 90 seconds after the lower float switch opens the 150 second shutdown sequence begins The inlet water valve remains open until the upper float switch closes DCM 500BAH DCM 500BAH OS DCM 500BWH DCM 500BWH OS WIRING DIAGRAM WIRING DIAGRAM F 115 12076071 115 2076071 4 gee HW 5e j d DIECR K e S amp e GND STARTER
40. NP a a oo Protec TOR x do S V STARTER Cag GND STARTER a m i 0 BR Pa ete RESISTOR CAP RESISTOR UN CAP ph SYED il pew eT CAP ie ENR ge m FAN MOTOR ONLY AR COOLED BR MOTOR ONLY AR COOLED BR A l 180 THERMAL THERMAL THERMAL PROTECTOR THERMAL PROTECTOR PN y TAL EAR OTR gy y Y 99 ien FUSE 20A IR 350 VAC FUSE QOM R rar 350 VAC pe RE 6 tt POWER SWITCH POWER SWITCH BK BK qu SWITCH N DOOR SWITCH aeq i POWER PROTECT GEAR MOTOR D GEAR MOTOR E PROTECT RELAY Ben PROTECT RELAY BR BR p n AGITATING MOTOR 8k AGITATING MOTOR Bk DISPENSING MOTOR TRANS 0 01 FUSE 14 AS K o w gy 180 R FUSE MAI gk zav eK m ov LBU 105V WATER DISPENSE ww BR BRI n DISPENSE DISPENSE et en WATER VALVE 5 FUSE 05A BR COM WO 27 DBU NOISE KILLER NOISE KILLER ga Mig PW LBU FLUSH ORAN BKI WATER VALVE LBU um DAN KE MAKING CONTROL ey mo si NOISE KILLER Z DBU oro NOISE KILLER j i BREW ig 1E MAKING CONTROL ATE a L mE A aen 1 1 H NC h t 2325678 dh i BR WATER VALVI 1 ttt id CONTROL INLET Wo u BL Ne LN Oro 1 232546782310 32 4 BR 65 ae VALVE NOISE KILLER K2 3 Led z IAM NOISE KLLER DCM TER BOARD 11 OK DCM THER BOARD MERI IHW Control Board x2 Control Board a
41. NTROL em 3 g NOISE KLLER Deu NOISE KILLER 2 T HHM reper TE MAKING TCONTROLI JE gt _ aot BK RES ES A 4 dL an 8 z 773 CONTROL NETI NC Oni ft 23275274 33 1 VALV tH CONTROL INLET em Nc n No i 2325678350 32 1 VALVE i E NOSE KLLER Ki K2 K3 NOISE KILLER R IEW oH TER BOARD BK l x DOM TIMER BOARD l BK IW BK u pod FLOAT SWITCH EE FLOAT SWITCH T 224367 Tr mm 5 6 i Roo LU l Diii 1 23439193 a E Mini il im t n pe pa HGH PRESSURE rar DBU WITCH NOISE KILLER HIGH PRESSURE NOISE KILLER 2 T SWITCH BK WATER BR E DISPENSE KE DISPENSE DISPENSE EE SWITCH WE uR x R X BK ia y i MUN Y OWN 10 WATER CONTROL l 1 0047 RELAY WIBU DISPENSE GY L Wo o SENSOR WATER CONTROL 3s R RELAY P WIR 2 y P DISPENSE MODE y 5 BIN CONTROL SWITCH ICE MAKING CONTROL BN CONTROL 7 TE MAKING CONTROL oY SWITCH e LBU LBU WIRE COLOR CODE BLACK o ORANGE W BK WHITE BLACK BR BROWN P PINK W BR WHITE BROWN BLUE R RED WBU WHITE BLUE DARK BLUE VIOLET WHITE ORANGE GRAY WHITE WHITE RED LIGHT BLUE YELLOW 31 D Sequence of Electrical Circuit Dispensing 1 Continuous Dispense Agitating motor energizes for 6 seconds for every 12 seconds of accumulative dispense time Maximum dispense time per dispense switch activation
42. Pin 4 W T bis didis K5 Pin 6 W BR 5VDC sVDC 5b Ice Dispensing Portion Mode Component Control Board Sensor Control Board Other Sensor On Solenoid K2PmeiBU NeutravGND _ e0va0 ovac K5 Pin 2 W BU 5VDC OVD K5 Pin 1 W R T Sewer kspintwin R 5VDC SVbC 5c Water Dispensing Control Board Control Board Other On Off K2 Pin 8 DBU K4 Pin 2 LBU 24VAC OVAC K5 Pin 8 WH 5VDC ene K5 Pin 9 BK 5VDC 5VDC 45 V Removal and Replacement of Components IMPORTANT 1 Ensure all components fasteners and thumbscrews are securely in place after the equipment is serviced 2 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 3 Always install a new drier every time the sealed refrigeration system is 4 opened Do not replace the drier until after all other repair or replacement has been made Do not leave the system open for longer than 15 minutes when replacing or servicing parts A Service for Refrigerant Lines WARNING 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
43. RD u DCM THER BOARD HE ontrol Boar l x2 BK BK C FONT SWITCH m ena FLOAT SWITCH DOI3ISRISDTE Uomo 6 oo 180 t l 1 23458 1 23599193 eter L 8k H H a E 8K HIGH PRESSURE e peu SWITCH NOSE KLLER HIGH PRESSURE NOISE KLLER BR BK Uwe SWITCH 1 Ima TE WATER BK 1 em BR DISPENSE BK TBK Y R i3 H e R SENSOR KE DISPENSE DISPENSE pan v SWITCH MODE i AR ek x BK ia y 2 ae j Y IN P OWN ND WIBU W ospeNse R SENSOR AE DISPENSE MODE BIN CONTROL SWITCH b MAKING CONTROL SWITCH LBU LBU WIRE COLOR CODE BLACK o ORANGE W BK WHITE BLACK BR BROWN P PINK W BR WHITE BROWN R RED GY 30 7 High Pressure Switch When the high pressure switch opens the compressor stops immediately 60 seconds later the gear motor stops To restart allow time for the high pressure switch to close then move the power switch to the OFF position and then back to the ON position DCM 500BAH DCM 500BAH OS DCM 500BWH DCM 500BWH OS
44. STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W KWH 100 Ibs POTABLE WATER WATER COOLED CONDENSER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN ICE MAKING SYSTEM HARVESTING SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION GEAR MOTOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 115 601 120 V 7 9 RLA 51 LRA 120 V 2 4 FLA 1 4 HP 120 V 0 9 FLA 55W 120 V 0 9 FLA 55W 120 V 0 2A 20A 20A 20A 20A Ambient WATER TEMP F Temp F 50 70 90 70 567 257 549 249 539 244 80 529 240 519 2335 509 231 90 500 227 495 224 481 218 100 472 214 464 210 428 194 Cubelet Compressed Flake Ice Approx 90 Ice 90 70 F Conductivity 200 us cm 40 Ibs 90 70 F 70 50 F 967 4 7 991 4 1 60 12 68 12 352 71 2 251 44 3 26 x 22 1 2 x 40 661 x 571 x 1016 mm Stainless Steel Galvanized Steel Rear Net 245 Ibs 111 kg Shipping 269 Ibs 122 kg Permanent Connection Inlet 1 2 FPT Condenser Inlet 1 2 FPT Outlet 43 4 x2 Condenser Outlet 3 8 Auger type Direct Driven Auger 1 4 HP Gear Motor F
45. The icemaker will not start Fill Cycle for further details 2 When the reservoir is full the GM LED comes on and the gear motor starts If the GM LED does not come on or the gear motor does not start check that the following safety circuits are closed a high pressure switch DCM 500BAH and DCM 500BWH connector K4 terminals 9 and 10 DCM 500BAH OS and DCM 500BWH OS connector K4 terminals 5 and 6 b low water safety bin control ice making switch circuit connector K4 terminals 3 and 4 Next check for 115 120V at connector K1 COM and K1 NO on the control board to neutral If the GM LED is on and there is voltage at K1 COM to neutral and no voltage at K1 NO to neutral the control board is bad and should be replaced See wiring diagram III C 2 Ice Purge Cycle for further details 3 60 seconds after the GM LED comes on the COMP LED comes on and the compressor and fan motor start If the COMP LED does not come on 60 seconds after the gear motor starts check that the gear motor protect relay contacts connector K2 terminals 1 and 2 have closed If the COMP LED is on and the compressor and fan motor did not start check for 115 120V at X2 LBU and X2 BR on the control board to neutral If the COMP LED is on and there is voltage at X2 BR to neutral and no voltage at X2 LBU to neutral the control board is bad and should be replaced See wiring diagram III C 3 Freeze Cycle for further details c Dispensi
46. We ora e e BR START CAP 213 292MFD DBU POWER SWITCH BK DOOR SWITCH GEAR MOTOR PROTECT RELAY POWER PROTECT RELAY BR AGITATING MOTOR NOISE KILLER PW aeS o FUSE tA BK E LBU FUSE 1A gy WATER DISPENSE s BR D DISPENSE um WATER VALVE rs WATER VALVE es NOISE KILLER NOISE KLLER EAR P Mg LBU FLUSH DRAIN FLUSH DRAIN WATER VALVE LBU WATER VALVE oeu GE AKNG CONTROL m eas NOISE KILLER LE NOISE KILLER TE MAKING CONTROL u al 20 xt Wr SWITCH Bo i M rg Jt 3 cs CONTROL INLET a T LECI CONTROL INLET s3 T R VALVE amp ds 3it 134 5 3 59 3 BR WATER VALVE HH o Ligt 5 NOSE KLLER e E S e Del 3 NOSE KLLER Eg DCM TIMER BOARD BK Mgr x DCM TIMER BOARD as Control Board oni poen FLOAT SWITCH FLOAT SWITCH ES E 5 E i id 180 01 23456 1 HH He HGH PRESSURE 1 nee p H HGH PRESSURE NOSE KLLER WATER ospense SENSOR KE DISPENSE DISPEN SWITCH
47. anitizing Solution Dilute 0 82 fl oz 25 ml of a 5 2596 sodium hypochlorite solution chlorine bleach with 1 6 gal 6 0 I of warm water d Sanitizing Procedure Following Cleaning Procedure 1 Make sure the control switch is in the OFF position the power supply is off and the water supply line shut off valve is closed 2 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 4 Pour the sanitizing solution over the extruding head until the evaporator assembly and the reservoir are full and the solution starts to overflow into the drain pan 5 Replace spout A spout B and the front cover of the storage bin in their correct positions 6 Allow the icemaker to sit for about 10 minutes before operation 7 Move the power switch to the ON position and replace the panels in their correct positions Turn on the power supply then move the control switch to the ICE position Make ice using the solution until the icemaker stops making ice 8 Move the control switch to the DRAIN position and allow the solution to drain for 5 minutes 9 Move the control switch to the ICE position Open the water supply line shut off valve to supply water to the reservoir 10 After the gear motor starts move the control switch to the DRAIN position and allow the water system to drain for 5 minutes 11 Move the control switc
48. as 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 13 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 14 Replace the fan motor assembly in its correct position 15 Replace the drip tray and drip tray hose in their correct positions Secure the hose to the tee Pour water into the drip tray and check for leaks 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 56 F Removal and Replacement of Water Cooled Condenser 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 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 apron panel then remove the left side panel 3 Recover the refrigerant and store it in an approved container 4 Disconnect the drip tray hose from the tee Remove the four screws securing the drip tray then remove the drip tray and hose 5 Close the condenser water supply line shut off valve then open the condenser water supply line drain valve 6 Attach a compressed air or carbon dioxide sup
49. cemaker water dispenser water supply line drain valve 2 Move the dispense mode switch to the CONTINUOUS position then dispense all of the ice from the storage bin 3 Move the control switch to the DRAIN position and allow the water system to drain for 5 minutes Note If the unit is running the drain valve will not open until 2 5 minutes after the control switch is moved to the DRAIN position This allows the components to cycle down 4 Attach a compressed air or carbon dioxide supply to the icemaker water dispenser 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 valve After blowing out the inlet water valve move the control switch to the OFF position 6 Close the icemaker water dispenser water supply line drain valve 7 Turn off the power supply then remove the front panel and move the power switch to the OFF position 8 Remove the front cover of the storage bin Clean the storage bin liner and the front cover of the storage bin using a neutral cleaner Rinse thoroughly after cleaning Replace the front cover of the storage bin and the front panel in their correct positions Note If your unit has a water co
50. ctivated and a 150 second shutdown sequence begins After the bin control has been open for 90 seconds the compressor and fan motor stop the agitating motor operates for 0 6 seconds and 60 seconds later the gear motor stops DCM 500BAH DCM 500BWH DCM 500BAH OS DCM 500BWH OS 29 WIRING DIAGRAM WIRING DIAGRAM 115 020 60 1 1 145 12076071 L N THERMAL COME M R Mita ER OUR x o GND va GND O STARTER te 0 x BR RESISTOR C l RESISTOR quoe i a ou I iT START CAP ALSO DUE ENR up 7 HEATER UP og 5 ay BR MOTOR ONLY AR COOLED CHL YAR COOLED sw igu MODEL LBU KN Y Prec To OO
51. e 9s f GEAR MOTOR GEAR MOTOR PROTECT RELAY ELAY PROTECT RELAY 3 TS Hg SEES pi rs AGTATING MOTOR K AGITATING MOTOR BK BU DISPENSING MOTOR BR SOLENOD NOGE KLLER TRANS 40 10 LBU R FUSE MAI Bk zav go LW ov LBU DISPENSE SWITCH WATER VALVE WATER VALVE 105V FUSE 05A BR NO o OBU NOISE KLLER NOISE KILLER ot fgg P IEW LBU FLUSH ORAIN Lid i FLUSH RANI WATER VALVE LBU WATER VALVE ea isi KE ANG cor bmg a NOISE KILLER DBU NOISE KILLER m i gol ig TEANG CONTRODI te Ei ine mi 13 CONTROL INLET E n T i G t 23 58178 4 BR X WATER VALVE 3 1 d Um A CONTROL INLET 6 mj jt NO 1 23258783910 s 3 i BR NOISE KILLER K1 K2 Kg Cg n E ul As NOISE KLLER DCH THER 11 KT OCM TIER BOARD T tao IET ont Boa Control Board FLOAT SWITCH FLOAT SWITCH 1 13315818698 R BU Ke s RI BUI T 1 2341 6 1 3 7 67 i LL T T HIGH PRESSURE 58 7 T 7 L Deu SWITCH NOISE KILLER HIGH PRESSURE NOISE KILLER R ore Bg ing EMIT E K E Es Y R SENSOR KE SPENSE DISPENSE Roy AS iod dl SWITCH MODE Ue R 3 y ko on ed T3 WATER CONTROL DISPENSE ELAY SENSOR WATER CONTROL Vui Wi RELAY a4 7 0 DISPENSE MODE E 4 BN CONTROL SWITCH KE NAAN CONTROL BN CONTROL smrcu 7 E MAKING CONTROL GY Gy LBU WIRE COLOR CODE BLACK o ORANGE W BK WH
52. ear Motor Agitating Motor 115V Out 115V Out Control Board Part Number 2A1592 01 15 3715B000 Q b DCM 500BAH OS DCM 500BWH OS Flush Switch Must be left in the P position otherwise the internal drain Bin Control timer will not operate Dispensing Components Control Switch See III B Wiring Diagrams Low Water Safety Counter Reset Button not tor details High 10 5V used in this application Pressure He AG ja 6 E 4 CC looooo o POWER LED board revision level lights when indicated by last 2 digits on label 9 power is supplied WTR LED ICE LED AM LED lone baerii X5 Relay X4 Relay X3 Relay GM LED Dispensing Shutter Solenoid Agitating Motor POWER O Water Valve Dispensing Auger X1 Relay Motor COMP LED Gear Motor X2 Relay comp Non m o eu Compressor Fan Motor FLUSH i X6 Relay Drain Valve looooooo000 ps SG TIT TANN 1 NO COM NC 24V Supply of LS Gear Motor 24V In In 115V In Protect Relay DISP TIM Drain Valve 24V In Circuit 115V In 24V Out Dis Gear Motor pensing Dispensing Motor Agitating Motor 15V Out Water Valve 115V Out 115V Out 24V Out Control Board Part Number 2A2649 01 16 2 Features The control board provides the following safeguards Provides component protection during low water supply Purges remaining ice in the evaporator at startup and shutdown Pro
53. ector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 3 Evacuation and Recharge R 404A 1 Attach a vacuum pump to the system Be sure to connect the 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 service 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 4 Close the low side valve and high side valve on the service manifold 5 Disconnect the vacuum pump and attach a refrigerant service cylinder to the high side line Remember to loosen the connection and purge the air from the hose See the nameplate for the required refrigerant charge Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No 700 88 be used 6 A liquid charge is recommended for charging an R 404A system Invert the service cylinder and place it on scales Open the high side valve on the service manifold 7 Allow the system to charge
54. emove the bolts securing the lower housing to the gear motor Lift the evaporator up slightly 7 Remove the gear motor drain pan bolts See Fig 3 ee Gear Motor 8 Disconnect the wiring from the gear motor Cover Screws then remove the gear motor from the drain pan Gear Motor Cover 9 Remove the gear motor bracket from the old gear motor and attach to the new gear motor 10 Remove the spline coupling and gear motor cover from the old gear motor and attach to the new gear motor The narrow side of the gear motor cover should be towards the evaporator After tightening the mounting screws apply silicone caulk to the heads to seal them Gear Motor Drain Pan Bolts and Washers 11 Place the new gear motor in the drain pan Gear Motor Bracket M 12 Using the gear motor drain pan bolts and PEN washers secure the gear motor and drain Gear Motor pan to the drain pan bracket Bracket Bolts ia e 13 Connect the gear motor wires 14 Lower the evaporator down and secure it to Drain Pan the gear motor Drain Pan poe 15 Replace the evaporator bracket in its Bracket Bolts correct position 16 Replace spout A spout B and the front cover of the storage bin in their correct positions Fig 3 55 17 Move the power switch to the ON position then replace the panels in their correct positions 18 Turn on the power supply then move the contro
55. er then place the new drier in position 13 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 14 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 15 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 16 Connect the flare connections 17 Close the condenser water supply line drain valve then open the condenser water supply line shut off valve 18 Check for water leaks 19 Replace the drip tray and drip tray hose in their correct positions Secure the hose to the tee Pour water into the drip tray and check for leaks 58 20 Move the power switch to the ON position then replace the panels in their correct positions 21 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process H Adjustment of Water Regulating Valve Water Cooled Model Only The water regulating valve also called water regulator is factory adjusted No adjustment is required under normal use Adjust the water regulator if necessary using the following procedures 1 Prepare a thermometer to check the condenser drain temperature Attach a pressure gauge to the high side
56. ghly with clean water Remove the snap pin shaft and actuator Remove spout B spout A and their gaskets 10 Wipe the shutter located above the ice dispensing spout thoroughly with a clean cloth 11 Reassemble the bin control assembly and replace all parts in the reverse order of which they were removed 12 Pour warm water into the storage bin and melt any remaining ice Clean the storage bin liner and the front cover of the storage bin using a neutral cleaner Rinse thoroughly after cleaning Replace the front cover of the storage bin in its correct position 13 Move the power switch to the ON position and replace the panels in their correct positions Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process Bin Control Bracket Snap Pin Water Dispensing Nozzle Shaft Ice Dispensing Spout Actuator Spout Cover Fig 7 Fig 8 66 B Maintenance This icemaker must be maintained individually referring to the instruction manual and labels provided with the icemaker The schedule below is a guideline More frequent maintenance however may be required depending on water quality the icemaker s environment and local sanitation regulations Consult with your local distributor about inspection and maintenance service To obtain the name and phone number of your local distributor visit www hoshizaki com or call Hoshizaki Technical Supp
57. gn without prior notice Il General Information A Construction 1 DCM 500BAH OS Evaporator Assembly Storage Bin Inlet Water Valve c o 4 YN Oo Seg x D c Agitator Ice Dispensing Auger Agitating Motor Dispensing Motor Compressor Control Box Power Switch Door Switch Gear Motor Control Switch Dispense Mode Switch y Air Cooled Condenser s E o e 0 lt _ o i 5 Dispensing Water Spout Cover 2 DCM 500BWH OS n Valve Expansio Spout A Drain Water Valve Evaporator Assembly Ice Dispensing Storage Bin Auger Agitating Motor Dispensing Motor Agitator Dispensing Water Valve In a LQ ONA Y M ax Y A T i om x S N LESS Z 7 V Drier L J 2 gt 2 1 E S3 3 N FE 5 2 a o 9 i o go 5 ze x Oo 5 9o r 9 B E o 2 0 o O gt 9 i gt os 3 2 E dE s o 5 amp 9 5 5 2 8 35 lt B Q O z 9 8 E 83 E o e o a Condenser Spout Cover 10 B Ice Making Unit 1 DCM 500BAH OS DCM 500BWH OS Extruding Head and Cubelet Cutter Upper Bearing zu oe Head Cap Screw Washer
58. h to the ICE position to start the automatic icemaking process Allow the icemaker to run for about 30 minutes then clean and sanitize the dispensing components as outlined below 2 Dispensing Components Perform after cleaning and sanitizing the water system as outlined above a Cleaning Solution Dilute 9 6 fl oz 0 29 I of recommended cleaner Hoshizaki Scale Away with 1 6 gal 6 0 I of warm water b Sanitizing Solution Dilute 0 82 fl oz 25 ml of a 5 25 sodium hypochlorite solution chlorine bleach with 1 6 gal 6 0 I of warm water c Cleaning and Sanitizing Procedure 1 Move the control switch to the OFF position then turn off the power supply 2 Remove the front and top panels then move the power switch to the OFF position 65 3 Remove the front cover of the storage bin 4 Remove the motor bracket thumbscrews first from the vertical plane and then from the horizontal plane While holding on to the corresponding agitator or auger move the agitating motor or the dispensing motor towards you Remove the agitator and the dispensing auger from the storage bin See Fig 6 5 Remove the bin control assembly See Fig 7 6 7 8 Remove the spout cover ice dispensing spout and water dispensing nozzle See Fig 8 9 Immerse the agitator dispensing auger and parts removed in steps 5 through 8 in the cleaning solution and then in the sanitizing solution for about 15 minutes each Rinse the parts thorou
59. hen the lower float switch opens refill begins The water control relay de energizes the 90 second low water safety timer begins and the inlet water valve energizes The compressor fan motor and gear motor continue to run When the upper float switch closes the water control relay energizes the 90 second low water safety timer terminates and the inlet water valve de energizes If the upper float switch fails to close within 90 seconds after the inlet water valve energizes a 150 second shutdown sequence begins 90 seconds after the 90 second low water safety timer is complete the compressor and fan motor de energize 60 seconds later the gear motor de energizes The inlet water valve continues until the upper float switch closes Diagnosis Check that the reservoir fills If not check the water supply line clogged water filters dirty or sticking float switches inlet water valve screen water control relay contacts voltage to the inlet water valve and inlet water valve solenoid or drain valve leaking 7 Drain Cycle FLUSH LED is on 12 hour timer activates the flush cycle and a 150 second shutdown sequence begins 90 seconds after the 12 hour timer activates the compressor and fan motor de energize 60 seconds later the gear motor de energizes The drain valve then energizes and remains energized for 20 minutes Once the 20 minute drain timer is complete the 12 hour drain cycle timer resets and the fill cycle begins 8 Shutd
60. l switch to the ICE position to start the automatic icemaking process E Removal and Replacement of Self Contained Air Cooled Condenser IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repairs or replacement have been made 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 apron panel then remove the left side panel 3 Recover the refrigerant and store it in an approved container 4 Disconnect the drip tray hose from the tee Remove the four screws securing the drip tray then remove the drip tray and hose 5 Remove the four bolts securing the fan motor assembly to the floor of the machine then move the assembly to the side 6 Disconnect the condenser inlet and outlet piping 7 Remove the screws securing the condenser assembly then remove the assembly 8 Remove the shroud from the old condenser and attach it to the new condenser 9 Install the new condenser 10 Remove the drier then place the new drier in position 11 12 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 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 g
61. loat Switch Automatic Water Regulator Mechanical Bin Control Proximity Sw Hermetic Model RS43C2E CAA 219 Water Cooled Double Tube Type Copper Tube on Cylinder Thermostatic Expansion Valve R404A 14 1 oz 400g High 460 PSIG Low 290 PSIG High Voltage Cut out Relay Auto reset Overload Protector Auto reset Thermal Protector Fuse Auto reset High Pressure Control Switch Float Switch and Timer Spare Fuse Legs VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 4 DCM 500BWH OS AC SUPPLY VOLTAGE COMPRESSOR GEAR MOTOR AGITATING MOTOR DISPENSING MOTOR OTHERS MAXIMUM FUSE SIZE MAX HACR BREAKER USA ONLY MAX CIRC BREAKER CANADA ONLY MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs POTABLE WATER WATER COOLED CONDENSER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN ICE MAKING SYSTEM HARVESTING SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL DISPENSE CONTROL SYSTEM BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P
62. m wi K P l AR BU BK 1 234 56 j l BK HIGH PRESSURE l pau MUCH l NOSE KLIER HIGH PRESSURE NOISE KILLER i Sog Id oT TKI SWITCH BK a MENY y Iia 2 BR DISPENSE T R 5 SENSOR KE DISPENSE DISPENSE T H H T I SWITCH MODE R oT I Ed A ret 65 3 E ee THR NT Vy WATER CONTRO ga tall m ni FEE WATER cou L Y 0 0 DISPENSE MODE E l Yey O BIN CONTROL SWITCH KE MAKING CONTROLI a BIN CONTROL SWITCH 7 KE HAKNG CONTROL LBU WIRE COLOR CODE BK BLACK o ORANGE W BKT WHITE BLACK BR BROWN P PINK W BR WHITE BROWN BLUE R RED W BU WHITE BLUE DARK BLUE VIOLET WHITE ORANGE GRAY WHITE WHITE RED LIGHT BLUE YELLOW 33 E Performance Data 1 DCM 500BAH OS APPROXIMATE Ambient Water Temp F ICE PRODUCTION Temp CF 5 70 9 PER 24 HR 70 80 90 Ibs day kg day 100 340 154 323 147 304 138 APPROXIMATE ELECTRIC 70 CONSUMPTION 80 90 watts 100 APPROXIMATE WATER 70 CONSUMPTION PER 24 HR 80 09 79 1 9 90 48 179 46 175 7 gal day l day 100 41 154 39 4 37 13 EVAPORATOR OUTLET TEMP 70 F C 80 90 100 HEAD PRESSURE 70 80 90 PSIG kg cm G 100 SUCTION PRESSURE 70 PSIG kg cm G 80 90 100 TOTAL HEAT OF REJECTION 6300 BTU h AT 90 F WT 70 F Note 1 The data without marks should be used for reference only 2 We reserve the right
63. mended pressure c Dispensing Water 1 Coil winding open 1 Replace 2 Wiring to dispensing 2 Check for loose or open water valve connection Repair or Valve replace Board Check Procedure e Water Dispense Switch 1 See 5 Opti Serve OS defective OS only Sensors 2 Bad contacts push button only replace 5 Opti Serve OS Sensors Be sure to check all items in section IV C 4 Dipsensing prior to using this chart Use the following charts along with the wiring diagram to troubleshoot the OS sensors 1 No ice dispensed ToS Sensor 1 Dirty sensor 1 Clean using Scale Away 6 fl oz 0 8 I per 1 gal 3 8 I of water or other non abrasive cleaner below b Dispense Mode Switch 1 Move to desired setting 5 Bad contacts 2 Check for continuity and replace 3 Tighten c Control Board T Tighten 2 Defective 2 See II D 4 Control Board Check Procedure and chart 5a and 5b below 2 No water dispensed a OS Sensor 2 See chart 5c below b Dispense Mode Switch 1 Wrong setting 1 Move to desired setting 2 Bad contacts 2 Check for continuity and replace c Control Board 2 Defective 2 See II D 4 Control Board Check Procedure and chart 5c below 44 5a Ice Dispensing Continuous Mode Component Control Board Sensor Control Board Other Sensor On or Solenoid KePieiBU mo 120VA0 ovac l K5 Pin 5 Y 5VDC 0VDC K5
64. move the upper and lower front panels Confirm the power switch is in the ON position and the door switch is engaged 2 Turn on the power supply then move the control switch to the ICE position The POWER LED is on The POWER LED will not come on if the door switch is not engaged 3 Fill Cycle The inlet water valve energizes The reservoir fills The lower float switch closes Nothing occurs at this time The reservoir continues to fill until the upper float switch closes energizing the water control relay which closes the low water safety circuit and de energizes the inlet water valve Diagnosis Check that the inlet water valve fills the reservoir If not check for water supply line shut off valve closed clogged water filters clogged inlet water valve screen power circuit to the inlet water valve power switch door switch power protect relay contacts transformer fuses high pressure switch bin control control switch float switch water control relay contacts and the coil on the inlet water valve Check that the inlet water valve shuts off when the upper float switch closes If not check the float switch water control relay and inlet water valve 4 Ice Purge Cycle GM LED is on 60 second short cycle protection The 60 second timer starts the gear motor protect relay and gear motor energize Diagnosis Check that the gear motor starts If not check that the water control relay is energized inlet water valve
65. n blade does not 3 Replace move freely Compressor 1 Bearings worn out or 1 Replace cylinder valve broken water cooled model 2 Fan blade deformed 2 Replace fan blade 2 Mounting pad out of 2 Reinstall position Refrigerant Lines 1 Rub or touch other 1 Reposition lines or surfaces d Auger 1 Bearings or auger 1 Replace bearings or worn out auger See V F Removal and Replacement of Evaporator Assembly Components b e Gear Motor 1 Bearing or gear worn 1 Replace out damaged b f Evaporator 1 Scale on inside wall 1 Use SCALE AWAY of evaporator freezing solution to clean cylinder periodically See VI A Cleaning and Sanitizing Instructions If the water is found hard by testing install a softener 2 Replace 3 Overflow from a Water Supply 1 Water pressure too 1 Install a pressure reducing reservoir water does high valve not stop Inlet Water Valve 1 Diaphragm does not 1 Clean or replace close c Float Switch 1 Bad contacts 1 Check for continuity and replace d Water Control Relay 1 Bad contacts 1 Replace 4 Gear motor overload a Power Supply 1 Not within 1 Refer to nameplate and protector operates specifications correct frequently or fuse b Evaporator Assembly 1 Bearings or auger 1 Replace bearings or blows frequently worn out auger See V F 1 Upper Bearing Wear Check c Bin Control 1 Bad contacts 1 Check for c
66. ng Components DCM 500BAH DCM 500BWH 1 Ice Dispense Continuous Pressing the ice dispense switch closes terminals 6 and 5 at the K4 connector The DM LED comes on and the dispensing motor energizes If the DM LED does not turn on check continuity through the ice dispense switch and the dispense mode switch If the LED is on and the dispensing motor does not start check for 115 120V at connector K2 terminals 3 and 6 to a neutral With voltage at terminal 3 and not at terminal 6 the control board is bad and should be replaced Note The agitating motor will operate 6 seconds every 12 seconds of accumulative dispense time See III D 1 Continuous Dispense 2 Ice Dispense Portion Pressing the ice dispense switch closes terminals 6 and 7 at the K4 connector The DM LED comes on and the dispinsing motor energizes If the DM LED does not turn on check continuity through the ice dispense switch and the dispense mode switch If the LED is on and the dispensing motor does not start check for 115V at connector K2 terminals 3 and 6 to a neutral With voltage at terminal 3 and not at terminal 6 the control board is bad and should be replaced Note The agitating motor will operate 6 seconds every 12 seconds of accumulative dispense time See III D 2 Portion Dipsense d Dispensing Components DCM 500BAH OS DCM 500BWH OS See IV C 5 Opti Serve OS Sensors E Float Switch Depending on local water conditions scale may build up on
67. o FAN MOTOR p ONLY AR COOLED i Dr AR COOLED tay MODEL m wi LBU THERMAL PROTECTOR THERMAL VE Bc DBU FUSE 20A Q peu FUSE m 350 VAC W 0 POWER SWITCH POWER SWITCH Pa 8 5 BK DOOR SWITCH i all Iss DOOR SWITCH PC GEAR MOTOR Pe GEAR MOTOR RT s PROTECT RELAY POER FRU PROTECT RELAY Era g 3 E tS aE 3n 4 AGITATING MOTOR BK AGITATING MOTOR ak DISPENSNG NOTOR DISPENSING MOTOR NOISE KILLER iE 10 TT LBU FUSE A gk 2 go f Fust 1054 WATER DISPENSE BR prane EJ DISPENSE SWITCH WATER VALVE ne WATER VALE FUE OSA Lap 7 ROI 57 e ams NOISE KILLER NOISE_KILLER img P IE FLUSH ORANI o9 Bn FLUSH ORAN WATER VALVE LBU WE KE MAKING CONTROL 5 DBU 5 SWITCH NOSE KILLER Bu ICE MAKING CONTROL SWITCH ii M vas x en enm Es Edu e CONTROL INLETI OM NO 23 5 o o 9 NES Lii LN rio PO3i15 7835 32 f rar HATER VALVE d K2 IG Lig n Oey INR pop x Gone Boar Bot Wa i FLOAT SWITCH FLOAT SWITCH 1 1 6 BU 4 i and 1 13458 1 1348567853 Gank m l E H H I HGH PRESSURE oU UND L SWITCH NOISE KILLER HIGH PRESSURE En al ISE KILLER BR BK ggg IA SWITCH WATER IHM eT LL ee f eg ospense ts Y R dt R SENSOR oem Nu T y WR pot LI BK 1 W BK 3 ak Y S l on a WATER CONTROL wau pspise t
68. oled condenser leave the front panel off and go to the next section 68 2 On water cooled model only remove the water from the water cooled condenser 1 Make sure the control switch and the power switch are in the OFF position and that the power supply is off Remove the top apron and left side panels 2 Close the condenser water supply line shut off valve and open the condenser water supply line drain valve 3 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve 4 Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 5 Close the condenser water supply line drain valve 6 Replace the panels in their correct positions 69
69. omp and FMS energize As the water in the evaporator cools ice starts forming within 4 to 6 minutes This time frame depends on the inlet water and ambient temperature conditions UF S and LF S operate WV as needed to continue the ice making process This continues until BC shuts the icemaker down or power is turned off to the icemaker Drain Cycle 12 hour DT activates FLUSH LED is on after 150 second shutdown sequence Comp and FMS de energize 90 seconds after the 12 hour DT activates GMPR and GM de energize 60 seconds later DV then energizes and remains energized for 20 minutes Shutdown BC is activated and a 150 second shutdown sequence begins After BC has been open for 90 seconds Comp and FMS de energize AM energizes for 0 6 seconds and 60 seconds later GM de energizes Legend AM agitating motor BC bin control Comp compressor DT drain timer FMS self contained fan motor GM gear motor GMPR gear motor protect relay LF S lower float switch UF S upper float switch WCR water control relay WV inlet water valve uonisod NO 24 xoeq uoiMs 4ewod eui eAOW US NIVHO 24 ul uois o11uoo eu eoe d uonisod 1 24 uoyMs amod eui e ouu eouenbes uwopinus puooes 09 eui ssed g 6 ueiseu uwopinug Z 591 119 eouenbes uwopinus puooes 0G eu jnun ezi amp ieue jou seop urejp eui 99 ezeeJj y Buunp uonisod NIVHG 24 Bulyoums ueuM Aiquiesse
70. ontinuity and replace 2 Actuator does not 2 Clean actuator or replace move freely bin control assembly d Safety Switch and 1 Switch misaligned 1 Check and correct or Relay contacts bad replace e Control Board 1 Erratic operation of 1 See II D 4 Control Board gear motor relay Check Procedure 42 4 Dispensing Problem Possible Cause 1 No ice dispensed a Power Supply 1 OFF position 1 Move to ON position 2 Tighten replace 4 Not within 4 Refer to nameplate and specifications correct storage bin 2 Ice bridge or ice block 2 Melt ice resupply with 3 Agitating motor 3 Check replace defective C Ice Dispense Switch 1 Opti Serve sensor 1 See 5 Opti Serve OS defective OS only Sensors 2 Bad contacts push button only replace d Shutter Assembly solenoid replace tripped open 3 Bearing worn out 3 Replace 4 Wiring to gear motor 4 Check for loose connection or open circuit and replace wiring as needed 5 Defective capacitor 5 Replace auger g Control Board 1 Defective 1 See II D 4 Control Board Check Procedure Head auger 2 Foreign matter 2 Remove foreign matter interrupting agitator Solenoid loosening screws the parts and tighten 43 Problem Possible Cause 3 No water dispensed a Power Supply 1 OFF position 1 Move to ON position b Water Supply 1 Water supply off or 1 Check and get pressure too low recom
71. orator assembly is completely full 7 Replace spout A spout B and the front cover of the storage bin in their correct positions 8 Allow the icemaker to sit for about 10 minutes before operation If you placed a clamp on the reservoir hose in step 6 remove it before operation 9 Move the power switch to the ON position and replace the panels in their correct positions Turn on the power supply then move the control switch to the ICE position Make ice using the solution until the icemaker stops making ice Note This unit will not run without the front panel in position 10 Move the control switch to the DRAIN position and allow the solution to drain for 5 minutes 11 Move the control switch to the ICE position Open the water supply line shut off valve to supply water to the reservoir 12 After the gear motor starts move the control switch to the DRAIN position and allow the water system to drain for 5 minutes Note If you do not sanitize the unit move the control switch to the ICE position after the water system drains Allow the icemaker to run for about 30 minutes then move the control switch to the OFF position Turn off the power supply then remove the front panel and front cover of the storage bin Go to step 12 in IV A 2 c Cleaning and Sanitizing Procedure 64 13 Move the control switch to the OFF position then turn off the power supply 14 Close the water supply line shut off valve c S
72. ort at 1 800 233 1940 in the USA WARNING 1 Only qualified service technicians should attempt to service or maintain this icemaker 2 Disconnect power before performing maintenance Maintenance Schedule Frequency Area sk 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 Icemaker 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 like Zud or Bon Ami Every 6 Icemaker and Clean and sanitize per the cleaning and sanitizing instructions provided in Months Storage Bin this manual Evaporator Wipe down with a clean cloth and warm water Slowly pour one cup of Condensate Drain sanitizing solution prepare as outlined in the sanitizing instructions in Pan and Gear this manual into the evaporator condensate drain pan Be careful not to Motor Drain Pan 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 and Bin Check to make sure they are clear Drains Yearly Inlet Water Valve Close the water supply line shut off valve and drain the water system and Drain Valve Clean the inlet water valve screen and clean and inspect the drain val
73. own The bin fills and activates the bin control A 150 second shutdown sequence begins After the bin control has been open for 90 seconds the compressor and fan motor stop the agitating motor energizes for 0 6 seconds and 60 seconds later the gear motor stops Diagnosis Check that the bin control paddle is activated and that the bin control switch opens If the compressor and gear motor fail to stop check the bin control proximity switch and control board relays B Ice Production Check To check production prepare a bucket or pan to catch the ice and a set of scales to weigh the ice After the icemaker has operated for 10 to 20 minutes catch the ice production for 10 minutes Weigh the ice to establish the batch weight Multiply the batch weight by 144 for the total production in 24 hours When confirming production or diagnosing low production see Performance Data 37 C Diagnostic Charts 1 No Ice Production Possible Cause 1 The icemaker will not a Power Supply 1 Off blown fuse or 1 Turn on replace or reset start Fill Cycle tripped breaker z Tighten replace specifications correct a too low recommended pressure Power Switch 1 Move to ON postion replace engaged replace specifications correct replace 1 Coil winding open 1 Replace Fuses 2 1 Blown 1 Check for short circuit and replace Control Switch 1 OFF or DRAIN 1 Move to ICE position position
74. ply to the condenser water supply line drain valve 7 Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 8 Disconnect the condenser water inlet and outlet piping and the refrigeration inlet and outlet piping at the condenser Remove the old condenser and install the new condenser Remove the drier then place the new drier in position Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 13 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 14 Close the condenser water supply line drain valve then open the condenser water supply line shut off valve 9 10 11 12 x N 15 Check for water leaks 16 Replace the drip tray and drip tray hose in their correct positions Secure the hose to the tee Pour water into the drip tray and check for leaks 17 Move the power switch to the ON position then replace the panels in their correct positions 18 Turn on the powe
75. r supply then move the control switch to the ICE position to start the automatic icemaking process 57 G Removal and Replacement of Water Regulating Valve Water Cooled Model 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 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 apron panel then remove the left side panel 3 Recover the refrigerant and store it in an approved container 4 Disconnect the drip tray hose from the tee Remove the four screws securing the drip tray then remove the drip tray and hose 5 Close the condenser water supply line shut off valve then open the condenser water supply line drain valve 6 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve 7 Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 8 Disconnect the capillary tube at the condenser outlet 9 Disconnect the flare connections of the valve 10 Remove the screws and the valve from the bracket 11 Install the new valve 12 Remove the dri
76. r 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 52 3 Remove the apron panel then remove the left side panel 4 Recover the refrigerant and store it in an approved container 5 Disconnect the drip tray hose from the tee Remove the four screws securing the drip tray then remove the drip tray and hose 6 Remove the front cover of the storage bin Remove spout B then remove spout A See Fig 1 7 Remove the extruding head heater then remove the allen head cap screws securing the extruding head Using the cutter lift out the auger assembly 8 Remove the evaporator bracket and disconnect the water hoses 9 Disconnect the inlet and outlet tubing 10 Remove the allen head cap screws securing the evaporator to the lower housing 11 Lift off the evaporator 12 Inspect the mechanical seal and O ring prior to installing the new evaporator The mechanical seal consists of two parts One moves along with the auger and the other is fixed on the lower housing 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 13 Make sure the lower mechanical seal is in place then place the new evaporator in posi
77. race 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 11 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 12 Attach the expansion valve bulb to the suction line in the same location as the previous bulb The bulb should be at the 12 o clock position on the tube Be sure to secure the bulb with the clamp and holder and to insulate it 13 Place the expansion valve cover in position 14 Replace the drip tray and drip tray hose in their correct positions Secure the hose to the tee Pour water into the drip tray and check for leaks 15 Move the power switch to the ON position then replace the panels in their correct positions 16 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 49 D Removal and Replacement of Evaporator Assembly Components CAUTION Make sure the extruding head heater is installed and connected after service Cutter ETT Extruding Head 6 Heater Wm Extruding Head and Het Upper Bearing Auger Pin Evaporator Bracket Allen Head Cap Screw Washer S Evaporator Allen Head Cap Screw with Washer D P p Mechanical Seal Di 8 eec E Hex Head Bolt
78. rant and store it in an approved container 5 Remove the terminal cover on the compressor and disconnect the compressor wiring 6 Remove the discharge suction and process pipes 7 Remove the compressor hold down bolts washers and rubber grommets 8 Remove the compressor Unpack the new compressor package 9 Attach the rubber grommets of the prior compressor to the new compressor 10 11 12 Remove plugs from the suction discharge and process pipes Place the compressor in position and secure it using the bolts and washers Remove the drier then place the new drier in position 13 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 14 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 15 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 16 Connect the terminals and replace the terminal cover in its correct position 17 Replace the drip tray and drip tray hose in their correct positions Secure the hose to the tee Pour water into the drip tray and check for leaks 18 Move the power switch to the ON position then replace the panels in their correct positions 19 Turn on the power suppl
79. re Starter Start Relay 1 Bad contacts 1 Check for continuity and replace 2 Coil winding open 2 Replace 8 Tighten Start Capacitor or Run 1 Defective 1 Replace M e Compressor 1 Power supply not 1 Refer to nameplate and within specifications correct 2 Wiring to compressor 2 Check for loose or open connection repair or replace 8 Replace 4 Compressor locked 4 Replace and internal motor protector tripped 5 All components a Refrigerant 1 Low charge 1 See V B Service for run but no ice is Refrigerant Lines produced 2 Refrigerant line or 2 Remove the restriction or component restricted component and replace the drier 3 Air or moisture 3 Recover refrigerant trapped replace drier evacuate and recharge b Expansion Valve 1 Bulb loose 1 Secure bulb 2 Operating erratically 2 Check and replace 1 Defective 1 Replace Possible Cause 5 All components d Evaporator 1 Replace run but no ice is e Water Supply Line 1 Condenser water 1 Check and get produced continued water cooled model pressure too low or recommended pressure only off and high pressure control opens and closes frequently f Water Regulating Valve 1 Water regulating 1 Clean adjust or replace water cooled model valve set too high or only clogged water cooled model only 2 Low Ice Production Possible Cause 1 Low ice production a Evaporator 1 Dir
80. refully before the icemaker is serviced or maintenance operations are performed Only qualified service technicians should install service and maintain the icemaker Read the warnings contained in this booklet carefully as they give important information regarding safety Please retain this booklet for any further reference that may be necessary CONTENTS NR 5 Leid MEET TEE om 5 1 DGM 500BAH T 5 PAM Up oe EE 6 7 4 DCM 500BWH OS E EOE 8 Il General 9 Pi 9 B lce Making 11 G Sequence Ol Me 12 Um E T 12 2 Ilce Purge Cycle 60 12 3 Freeze 12 rris Ae RO 12 OE N ener eeaenees 12 14 1 Control Board TAY ON 15 a DCM BODBAH DONM BSODBMDI ice eundi etras uten oU MY t ean tuu es quai dris 15 b DCM 500BAH OS 5 5 nennen ennt 16 P 17 3 Controls and Adjust BlilS cocum de ee pert napa 18 4 Control Board Check
81. rol Box 2 Loose terminal 2 Repair terminal connection Control Board 1 Defective 1 See II D 4 Control Board Check Procedure 2 Fill cycle will not a Water Supply 1 Water supply off or 1 Check and get terminate pressure too low recommended pressure b Float Switch 1 Connector 1 Reconnect disconnected 2 Float does not move 2 Clean or replace freely 3 Defective switch 3 Check and replace c Water Control Relay 1 Contacts sticking 1 Replace 2 Coil winding open 2 Replace d Drain Valve 1 Valve seat won t seal 1 Clean or replace and water leaking e Hoses 1 Disconnected or 1 Reconnect or replace damaged f Control Board 1 Defective 1 See 1 0 4 Control Board Check Procedure 39 Possible Cause 3 Ice purge cycle will a Water Control Relay 1 Low water safety 1 Replace not start circuit open bad contacts Control Switch 1 Bad contacts 1 Check for continuity and replace Bin Control 1 Open 1 Bin full check for continuity on proximity Switch Control Board 1 Fails to operate gear 1 See II D 4 Control Board motor relay Check Procedure Gear Motor Fuse 1 Blown 1 Check gear motor amperage bearing wear see V F 1 Upper Bearing Wear Check and supply voltage Protector bearings supply voltage Gear Motor 4 Freeze cycle will not a Gear Motor Protect a nd Control Board 1 Defective 1 See II D 4 Control Board Check Procedu
82. se By RELA WATER CONTROL WIE SENSOR 5 re ane ees wr R RELAY I e a DISPENSE MODE Y CN 0 Y oi d BN CONTROL SWITCH Ets CONTROL BIN CONTROL SWITCH Sito CONTROL LBU LBU WIRE COLOR CODE BLACK o ORANGE W BK WHITE BLACK BR BROWN P PINK W BR WHITE BROWN BLUE 8 RED WBU WHITE BLUE LIGHT BLUE YELLOW 25 DARK BLUE VIOLET WHITE ORANG GRAY WHITE W R WHITE RED mi 2 Ice Purge Cycle Upper float switch closes water control relay energizes inlet water valve closes gear motor starts gear motor protect relay energizes DCM 500BAH DCM 500BWH WIRI DCM 500BAH OS DCM 500BWH OS G DIAGRAM WIRING DIAGRAM F 115 12076071 4 F lan 1 L N L N THERMAL THERMAL
83. sition 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 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 1 4 Remove the apron panel then remove the left side panel 5 Remove the extruding head heater then 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 extruding head heater and cutter in their correct positions 51 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 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
84. 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 1 4 Remove the apron panel then remove the left side panel 5 Remove the extruding head heater then 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 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 the extruding head heater in its correct position 9 Replace spout A spout B and the front cover of the storage bin in their correct positions 10 Move the power switch to the ON position then replace the panels in their correct positions 11 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 4 Removal and Replacement of Evaporator 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 Move the control switch to the DRAIN position and drain all of the water from the evaporator 2 Afte
85. tic discharge It is especially important to touch the metal part of the unit before handling or replacing the board 3 Do not touch the electronic devices on the control board or the back of the control board to prevent damage to the control board 4 Do not change wiring and connections Especially never misconnect terminals 5 Always replace the whole control board if it goes bad 6 Do not short out power supply to test for voltage 1 Control Board Layout a DCM 500BAH DCM 500BWH Flush Switch Must be left in the P position otherwise the internal drain timer will not operate Counter Reset Button not used in this application Portion Control Timer DISP TIME FLUSH LED X5 Relay Drain Valve 24V Supply ou Drain Valve o4y n 24V Out Dispensing Motor 115V Out Dispensing Components See Ill Bin Control Control High B Wiring Switch Pressure Diagrams Low Water 0 5y Switch for details Safety Tr nsfommar Oo 6 8 2 9 G 7 E Z o0oO0O 0 0000 0 Microprocessor board revision level indicated by last 2 digits on label DM LED X4 Relay Shutter Solenoid AM LED Dispensing Auger X3 Relay Motor Agitating Motor POWER LED lights when power is supplied to the board _ POWER AM COMP LED COMP Li X2 Relay Compressor GM GM LED 7 X1 Relay Fan Motor Gear Motor Gear Motor 115V In 115V In Protect Relay 115V In Circuit G
86. tion Secure the evaporator to the lower housing using the allen head cap screws 14 Remove the drier then place the new drier in position 15 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 16 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 17 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 18 Install the auger assembly with the upper part of the mechanical seal attached and tighten down the allen head cap screws 19 Replace the evaporator bracket and reconnect the water hoses 20 Replace spout A spout B and the front cover of the storage bin in their correct positions 21 Replace the drip tray and drip tray hose in their correct positions Secure the hose to the tee Pour water into the drip tray and check for leaks 22 Move the power switch to the ON position then replace the panels in their correct positions 23 Turn on the power supply then move the control switch to the ICE position to start the automatic icemaking process 53 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
87. ty or defective 1 Clean or replace b Bin Control 1 Erratic sticking 1 Clean or replace defective c Drain Valve 1 Leaking water 1 Clean or replace d Expansion Valve 1 Bulb loose 1 Secure bulb 2 Operating erratically 2 Check and replace e Refrigerant Charge 1 Low charge 1 See V B Service for Refrigerant Lines 2 Overcharge 2 See V B Service for Refrigerant Lines f Refrigerant Line 1 Refrigerant line or 1 Repair replace the component restricted clogged line component and replace the drier g High Side Pressure 1 Dirty air filter or 1 Clean Too High condenser 2 Ambient or 2 Reduce temperature condenser water temperature too warm 3 Fan motor slow rpm 3 See 3 2 a Fan Motor 4 Fan motor capacitor 4 Check and replace 5 Condenser water 5 Check and get pressure too low or off recommended pressure water cooled model only 6 Water regulating 6 Clean adjust or replace valve set too high or clogged water cooled model only h Compressor 1 Inefficient compressor 1 Replace 2 Faulty thermal 2 Replace compressor protector overload 3 Faulty capacitor 3 Replace starter 41 3 Other Possible Cause 1 Icemaker will not stop a Bin Control 1 Actuator sticking 1 Adjust or replace when bin is filled with 2 Proximity switch 2 Replace ice closed 2 Abnormal noise a Fan Motor except 1 Bearing worn out 1 Replace 3 Fa
88. ure Before replacing a control board that does not show a visible defect and that you suspect is bad always conduct the following check procedure This procedure will help you verify your diagnosis a Power Supply 1 Move the control switch to the ICE position The POWER LED should come on If the POWER LED is off check that the power supply is on the power switch is in the ON position the door switch is engaged and the control switch is in the ICE position Check the transformer 10 5V secondary circuit and fuse If the 10 5V secondary circuit K4 pins 1 and 2 has proper voltage and the POWER LED is off the control board is bad and should be replaced If the secondary circuit does not have proper voltage see IV C 1 1 The icemaker will not start Fill Cycle for further details b Ice Making Components 1 Confirm the reservoir is full of water If no water is in the reservoir make sure that the control switch is not in the DRAIN position and that the unit is not in the 12 hour drain cycle Also check the water supply line water shutoff valve and water filters In the fill cycle the POWER LED is the only LED lit on the control board If no water is filling the reservoir check for 24V at connector K2 terminal 7 to neutral and connector K3 DBU to neutral If there is 24V at connector K2 terminal 7 to neutral and no voltage at K3 DBU to neutral the control board is bad and should be replaced See IV C 1 1
89. ve Condenser Inspect Clean if necessary by using a brush or vacuum cleaner Icemaker 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 the Service Manual for details 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 67 C Preparing the Icemaker for Long Storage CAUTION When the icemaker is not used for two or three days under normal conditions it is sufficient to only move the control switch to the OFF position When storing the icemaker for extended time or in sub freezing temperatures turn the water off and drain out all water from the water lines and remove the ice from the storage bin The storage bin should be cleaned and dried Drain the icemaker water hoses using air or carbon dioxide to prevent damage at sub freezing temperatures 1 Remove the ice from the storage bin drain the water system and remove the water from the icemaker water dispenser water supply line 1 Close the icemaker water dispenser water supply line shut off valve and open the i
90. vides short cycle protection for the compressor a LED Lights The POWER LED indicates control voltage and will remain on unless a control voltage problem occurs An LED illuminates for each relay as it is energized For more information see II C Sequence of Operation Energized Time LEDs are Frequency LEDs are Cycle Relay G Fill POWER only As Needed Ice Purge X1 Drain Valve X6 FLUSH Every 12 Hours Dispensing Energized Time LEDs are Frequency LEDs are DM 60 seconds Ice Dispense X4 Opti Serv maximum ICE Every 12 seconds of Agitating Motor X3 AM AM 6 seconds accumulative dispense time Water Dispense X5 Opti Serv Only WTR WTR N A N A Legend AM agitating motor Comp compressor DV drain valve FMS self contained fan motor GM gear motor IDM ice dispensing motor shutter solenoid WTR dispensing water valve WV inlet water valve 17 3 Controls and Adjustments a Portion Control When the dispense mode switch is placed in the PORTION position a variable resistor located on the control board controls the ice dispense time The figures on the label indicate dispensing time sec When shipped the portion control is set at the minimum dispensing time 0 6 sec 911 43 DCM 500BAH OS DCM 500BWH OS Approximately 0 72 oz Amount of ice dispensed per second DCM 500BAH OS DCM 500BWH OS Approximately 1 2 oz DISPTIME 20 4 Control Board Check Proced
91. 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 1 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 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 CAUTION To help prevent water leaks be careful not to damage the surfaces of the O ring or mechanical seal 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 V D 1 Upper Bearing Wear Check indicates that it is out
92. wer Switch Agitator Dispensing Auger Control Switch Dispense Mode Switch Dispensing Motor Agitating Motor Fig 6 63 1 Water System a Cleaning Solution Dilute 9 6 fl oz 0 29 I of Hoshizaki Scale Away with 1 6 gal 6 0 I of warm water b Cleaning Procedure 1 Close the water supply line shut off valve 2 Move the dispense mode switch to the CONTINUOUS position then dispense all of the ice from the storage bin 3 Move the control switch to the DRAIN position and allow the water system to drain for 5 minutes Note If the unit is running the drain valve will not open until 2 5 minutes after the control switch is moved to the DRAIN position This allows the components to cycle down 4 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 5 Remove the front cover of the storage bin Remove spout B then remove spout A See Fig 6 6 Pour the cleaning solution over the extruding head until the evaporator assembly and the reservoir are full and the solution starts to overflow into the drain pan Note If there is excess scale on the extruding head fill the evaporator assembly and reservoir as described above then use a clamp on the reservoir hose between the reservoir and evaporator assembly to block flow Pour additional cleaning fluid over the extruding head until the evap
93. with liquid until the proper charge weight is met 8 If necessary add any remaining charge to the system through the low side Use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low side access port with the unit running 9 Close the service manifold valves and disconnect the service manifold hoses 10 Cap the access valves to prevent a possible leak 47 B Removal and Replacement of Compressor 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 Note When replacing a compressor with a defective winding be sure to install the new start capacitor and start relay supplied with the replacement compressor Due to the ability of the POE oil in the compressor to absorb moisture quickly the compressor must not be opened more than 15 minutes for replacement or service Do not mix lubricants of different compressors even if both are charged with R 404A except when they use the same lubricant 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 apron panel then remove the right side panel 3 Disconnect the drip tray hose from the tee Remove the four screws securing the drip tray then remove the drip tray and hose 4 Recover the refrige
94. y then move the control switch to the ICE position to start the automatic icemaking process 48 C Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigeration circuit exceeds the drier capacity and freezes up at 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 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 apron panel then remove the left side panel 3 Recover the refrigerant and store it in an approved container 4 Disconnect the drip tray hose from the tee Remove the four screws securing the drip tray then remove the drip tray and hose 5 Remove the insulation and the expansion valve bulb on the suction line 6 Remove the expansion valve cover and disconnect the expansion valve 7 Place the new expansion valve in position 8 Remove the drier then place the new drier in position 9 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG CAUTION 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 121 C 10 Use an electronic leak detector or soap bubbles to check for leaks Add a t

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