Hoshizaki DT-400BAH-OS Service Manual
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Hoshizaki DT-400BAH-OS Service Manual

Hoshizaki DT-400BAH-OS Service Manual

Cubelet icemaker / dispenser
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Cubelet Icemaker / Dispenser
Model
DT-400BAH-OS
SERVICE MANUAL
®
73155
Number:
Issued: 5-8-2008

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Summary of Contents for Hoshizaki DT-400BAH-OS

  • Page 1 Hoshizaki America, Inc. “A Superior Degree of Reliability” www.hoshizaki.com Cubelet Icemaker / Dispenser Model DT-400BAH-OS SERVICE MANUAL ® 73155 Number: Issued: 5-8-2008...
  • Page 2 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.

  • Page 3: Table Of Contents

    B. Wiring Diagram ... 16 1a. DT-400BAH-OS (auxiliary code: S-0) ... 16 1b. DT-400BAH-OS (auxiliary code: T-0 and later) ... 17 C. Sequence of Electrical Circuit – Ice Making (auxiliary code T-0 and later)... 18 1. Fill Cycle ... 18 .
  • Page 4 IV. Service Diagnosis ... 9 A. Diagnostic Procedure ... 9 B. Ice Production Check ... 30 C. Diagnostic Charts ... 31 1. No Ice Production ... 31 . Low Ice Production ... 34 3. Other ... 34 4. Dispensing ... 35 5.

  • Page 5: Specifications

    I. Specifications A. Icemaker AC SUPPLY VOLTAGE AMPERAGE MAXIMUM FUSE SIZE MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE QUALITY APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POTABLE WATER gal./24HR (gal./100 lbs.)

  • Page 6: General Information

    II. General Information A. Construction Control Box Power Switch Shutter Assembly Control Switch Dispense Mode Switch Spout Cover Inlet Water Valve Float Switch Reservoir Drain Water Valve Air-Cooled Condenser Dispensing Motor Dispensing Water Valve Dispense Controls Gear Motor Drain Pan Compressor Bin Control Storage Bin...

  • Page 7: Ice Making Unit

    B. Ice Making Unit Auger Cap Auger Sleeve Extruding Head Upper Bearing Allen Head Cap Screw O-Ring Drain Pan Auger Evaporator Cylinder Mechanical-Seal Insulation O-Ring Allen Head Cap Screw Housing-Lower Bearing Hex Head Bolt Spline Coupling Gear Motor...

  • Page 8: Sequence Of Operation

    C. Sequence of Operation The steps in the sequence are as outlined below. When power is supplied, the power switch is in the "ON" position, and the control switch is in the "ICE" position, the "POWER" LED on the control board comes on. 1.

  • Page 10: Control Board

    D. Control Board • A Hoshizaki exclusive solid-state control board is employed in DT-400BAH-OS Cubelet Icemaker / Dispenser. • All models are pretested and factory-adjusted. 1. Fragile, handle very carefully. . The control board contains integrated circuits, which are susceptible to failure due to static discharge.

  • Page 11: Control Board Layout

    1. Control Board Layout DT-400BAH-OS 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 "WTR" LED (X5 Relay) Dispensing Water Valve "FLUSH"...

  • Page 12: Features

    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. • Provides 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.

  • Page 13: Controls And Adjustments

    The figures on the label indicate dispensing time (sec.). When shipped, the portion control is set at the minimum dispensing time (0.6 sec.). DT-400BAH-OS ... . Approximately 0.7 oz. Amount of ice dispensed per second.

  • Page 14: Float Switch

    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 K terminals 1 and ) have closed.

  • Page 15: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. DT-400BAH-OS Inlet Water Valve Float Switch Water Supply Reservoir Overflow Dispensing Water Valve Condenser Drain Pan Water Level To Drain Evaporator Gear Motor Drier Condenser Fan Motor High Pressure Switch...

  • Page 16: Wiring Diagram

    B. Wiring Diagram 1a. DT-400BAH-OS (auxiliary code: S-0) * High Pressure Switch Cut-out 412± Cut-in 327±21 PSIG WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE...

  • Page 17: 1B. Dt-400Bah-Os (Auxiliary Code: T-0 And Later)

    1b. DT-400BAH-OS (auxiliary code: T-0 and later) * High Pressure Switch Cut-out 412± PSIG Cut-in 327±21 PSIG WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE...

  • Page 18: Sequence Of Electrical Circuit - Ice Making (Auxiliary Code T-0 And Later)

    WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED DT-400BAH-OS...

  • Page 19: Ice Purge Cycle

    Upper float switch closes, water control relay energizes, inlet water valve closes, gear motor starts, gear motor protect relay energizes. WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED DT-400BAH-OS...

  • Page 20: Freeze Cycle

    3. Freeze Cycle Compressor and fan motor start 60 seconds after gear motor starts. WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED DT-400BAH-OS...

  • Page 21: Hour Drain Cycle / Drain Switch

    "ICE" position. WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED 1 Hour Drain Cycle Manual Drain Cycle DT-400BAH-OS...

  • Page 22: Shutdown

    90 seconds, the compressor and fan motor stop, the agitating motor operates for 0.6 seconds, and 60 seconds later the gear motor stops. WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED DT-400BAH-OS...

  • Page 23: Low Water Safety

    150 second shutdown sequence begins. The inlet water valve remains open until the upper float switch closes. WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED DT-400BAH-OS...

  • Page 24: Safety Switch

    When the safety switch is activated, the safety relay energizes, and the icemaker shuts down. WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED DT-400BAH-OS...

  • Page 25: High Pressure Switch

    "OFF" position and then back to the "ON" position. WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED DT-400BAH-OS...

  • Page 26: Sequence Of Electrical Circuit - Dispensing

    Maximum dispense time per dispense switch activation is 60 seconds. After 60 seconds, the dispense switch must be disengaged and engaged again. WIRE COLOR CODE BLACK BROWN BLUE DARK BLUE GRAY LIGHT BLUE ORANGE PINK VIOLET WHITE YELLOW W/BK WHITE/BLACK W/BR WHITE/BROWN W/BU WHITE/BLUE WHITE/ORANGE WHITE/RED DT-400BAH-OS...

  • Page 27: Portion Dispense

    D.3.a) Portion Control." When shipped, the portion control is set at the minimum dispensing time (0.6 sec.). DT-400BAH-OS ... . Approximately 0.7 oz. Amount of ice dispensed per second. DT-400BAH-OS ... . Approximately 1. oz.

  • Page 28: Performance Data

    E. Performance Data APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day) APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. (TOTAL) gal. / day (l/day) EVAPORATOR OUTLET TEMP. °F (°C) HEAD PRESSURE PSIG (kg/cm SUCTION PRESSURE PSIG (kg/cm TOTAL HEAT OF REJECTION Note: The data without *marks should be used for reference.

  • Page 29: Service Diagnosis

    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.

  • Page 30: Ice Production Check

    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. When the lower float switch opens, refill begins.

  • Page 31: Diagnostic Charts

    C. Diagnostic Charts 1. No Ice Production Problem Possible Cause [1] The icemaker will not a) Power Supply start. (Fill Cycle) b) Water Supply c) Power Switch (Control Box) d) Safety Switch and Relay e) Transformer f) Fuses () g) Control Switch h) Water Control Relay i) Inlet Water Valve j) Float Switch...
  • Page 32 Problem Possible Cause [1] The icemaker will m) High Pressure Switch not start. (Fill Cycle) (continued) (continued) n) Plug and Receptacle (Control Box) o) Control Board [] Fill cycle will not a) Water Supply terminate. b) Float Switch c) Water Control Relay d) Drain Valve e) Hoses f) Control Board...
  • Page 33 Problem Possible Cause [3] Ice purge cycle will e) Gear Motor Fuse not start. (continued) f) Gear Motor Thermal Protector g) Gear Motor [4] Freeze cycle will not a) Gear Motor Protect start (compressor). Relay b) Control Board c) Starter (Start Relay) d) Start Capacitor or Run Capacitor e) Compressor...

  • Page 34: Low Ice Production

    2. Low Ice Production Problem Possible Cause [1] Low ice production. a)Evaporator b)Bin Control c) Drain Valve d)Expansion Valve e)Refrigerant Charge f) Refrigerant Line g)High-Side Pressure Too High h)Compressor 3. Other Problem Possible Cause [1] Icemaker will not stop a)Bin Control when bin is filled with ice.

  • Page 35: Dispensing

    Problem Possible Cause [] Abnormal noise. c) Refrigerant Lines (continued) d)Auger e)Gear Motor f) Evaporator [3] Overflow from a)Water Supply reservoir (water does not stop). b)Inlet Water Valve c) Float Switch d)Water Control Relay [4] Gear motor overload a)Power Supply protector operates frequently or fuse b)Evaporator Assembly...
  • Page 36 Problem Possible Cause [1] No ice dispensed. b) Ice Storage (continued) c) Ice Dispense Sensor d) Shutter Assembly e) Dispense Gear Motor f) Auger Mechanism g) Control Board [] Abnormal noise. a) Gear Motor or Gear Head b) Auger Mechanism c) Dispense Water Solenoid [3] No water dispensed.

  • Page 37: Opti Serve (Os) Sensors

    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. Problem Possible Cause [1] No ice dispensed. a) OS Sensor b) Change Switch (Dispense Mode...

  • Page 38: Removal And Replacement Of Components

    V. Removal and Replacement of Components 1. Ensure all components, fasteners, and thumbscrews are securely in place after the equipment is serviced. . 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.

  • Page 39: Service For Refrigerant Lines

    B. Service for Refrigerant Lines 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.

  • Page 40: Evacuation And Recharge (R-404A)

    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.
  • Page 41 d) Disconnect the 3 wiring connectors. e) Disconnect the wires from the high pressure switch and the drain valve. f) Remove the condensate hose from the hose bundle. g) Raise the insulation on the transport hose. Loosen the clamp and disconnect the transport hose from the evaporator.

  • Page 42: Removal And Replacement Of Compressor

    D. Removal and Replacement of Compressor 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.

  • Page 43: Removal And Replacement Of Expansion Valve

    E. Removal and Replacement of Expansion Valve 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.

  • Page 44: Removal And Replacement Of Evaporator Assembly Components

    F. Removal and Replacement of Evaporator Assembly Components Auger Spring Retainer Mechanical Seal Housing and Lower Bearing Barrier Gear Motor O-Ring Auger Cap (cutter) O-Ring Hex Head Bolt with Washer Spline Coupling Allen Head Cap Screw with Washer Auger Sleeve Allen Head Cap Screw Extruding Head...

  • Page 45: Upper Bearing Wear Check

    1. Upper Bearing Wear Check To ensure that the bearing inside the extruding head does not exceed the wear tolerance of .0", follow the instructions below. See Fig. 4. 1) Remove the refrigeration tray as outlined in "V.C. Removal of Refrigeration Tray." ) Remove the allen head cap screws and lift off the auger sleeve and remove the auger cap.

  • Page 46: Removal And Replacement Of Auger

    5) Place the new extruding head in place. 6) Replace the removed parts in the reverse order of which they were removed. 7) Replace the refrigeration tray in reverse order from which it was removed. 1. When reinstalling the refrigeration tray, make sure the drain hoses align properly over the drain tank in the rear of the machine.

  • Page 47: Removal And Replacement Of Evaporator

    4. Removal and Replacement of Evaporator 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.

  • Page 48: Removal And Replacement Of Mechanical Seal And Lower Housing

    16) Replace the lower front panel in its correct position. 17) Plug the icemaker back in. Move the control switch to the "ICE" position to start the automatic icemaking process. 5. Removal and Replacement of Mechanical Seal and Lower Housing 5a.

  • Page 49: Removal And Replacement Of Gear Motor

    14) Replace the refrigeration tray in the reverse order of which it was removed. 1. When reinstalling the refrigeration tray, make sure the drain hoses align properly over the drain tank in the rear of the machine. See Fig. . .

  • Page 50: Removal And Replacement Of Fan Motor

    G. Removal and Replacement of Fan Motor 1) Move the control switch to the "OFF" position. ) Unplug the icemaker from the electrical outlet. 3) Remove the lower cabinet stand panel. 4) Slide the refrigeration circuit tray forward as described below. See Fig. 3. a) Remove the screw and L-bracket at the base of the tray.

  • Page 51: Removal And Replacement Of Drain Valve

    9) 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. 10) Replace the water valve bracket in its correct position. 11) Reconnect the wire terminals. 1) Reconnect the fitting nut on the water valve.

  • Page 52: Removal And Replacement Of Dispensing System

    13) Open the water supply line shut-off valve. 14) Plug the icemaker back in and move the control switch to the "ICE" position. 15) Allow the icemaker to fill for two minutes. 16) Move the control switch to the "OFF" position and unplug the icemaker from the electrical outlet.
  • Page 53 7) Remove the four flat head screws and the gear motor. 8) Install the new motor. 9) Assemble the removed parts in the reverse order of which they were removed. 10) Plug the icemaker back in. Move the control switch to the "ICE" position to start the automatic ice making process.

  • Page 54: Cleaning And Maintenance

    A. Cleaning and Sanitizing Instructions - Water System 1. Cleaning Solution Dilute approximately 9.6 fl. oz. (0.9 l) of recommended cleaner, Hoshizaki "Scale Away" or "LIME-A-WAY" (Economics Laboratory, Inc.), with 1.6 gallons (6.0 l) of warm water. 2. Cleaning Procedure 1) Close the water supply line shut-off valve.

  • Page 55: Sanitizing Solution

    8) Allow the icemaker to sit for about 10 minutes before operation. If you placed a clamp on the reservoir hose in step 7, remove it before operation. 9) Plug the icemaker back in. Move the power switch to the "ON" position and replace the panels in their correct positions.
  • Page 56 8) Move the control switch to the "OFF" position. Remove the upper front, top and left side panels. 9) Move the power switch to the "OFF" postion. Unplug the icemaker from the electrical outlet. 10) Disconnect the ice transport hose from the spout, and pour fresh water into the ice transport hose to rinse out the solution and fill the evaporator and reservoir.

  • Page 57: Cleaning And Sanitizing Instructions - Dispensing Components

    Perform following the cleaning and sanitizing procedures for the water system. 1. Cleaning Solution Dilute approximately 9.6 fl. oz. (0.9 l) of recommended cleaner, Hoshizaki "Scale Away" or "LIME-A-WAY" (Economics Laboratory, Inc.), with 1.6 gallons (6.0 l) of warm water.
  • Page 58 8) Remove the thumbscrews, spout cover, ice dispensing spout, and water dispensing nozzle. See Fig. 10. 9) Immerse the parts removed in steps 4 through 8 in the cleaning and sanitizing solutions for about 15 minutes each. 10) Rinse these parts thoroughly with clean water. 11) Thoroughly wipe the shutter located above the ice dispensing spout.

  • Page 59: Maintenance

    1-800-33-1940 in the USA. 1. Icemaker and Storage Bin • Hoshizaki recommends cleaning this icemaker at least twice a year. More frequent cleaning, however, may be required in some existing water conditions. • The storage bin is for ice use only. Do not store anything else in the bin.

  • Page 60: Preparing The Icemaker For Long Storage

    D. Preparing the Icemaker for Long Storage 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 bin.

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