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Hoshizaki DCM-300BAH Service Manual

Cubelet icemaker/dispenser
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Cubelet Icemaker/Dispenser
Models
DCM-300BAH(-OS)
SERVICE MANUAL
Number: 73189
Issued: 1-5-2012

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Summary of Contents for Hoshizaki DCM-300BAH

  • Page 1 Hoshizaki Hoshizaki America, Inc. Cubelet Icemaker/Dispenser Models DCM-300BAH(-OS) SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com Number: 73189 Issued: 1-5-2012...
  • Page 2 Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, send an e-mail message, or write to the Hoshizaki Technical Support Department for assistance. Phone: 1-800-233-1940; (770) 487-2331 Fax: 1-800-843-1056;...

  • Page 3: Table Of Contents

    2. Sequence Flow Chart .....................11 C. Control Board ......................12 1. Control Board Layout ..................... 13 a) DCM-300BAH ....................13 b) DCM-300BAH-OS ..................... 14 2. LED Lights and Components ................. 15 D. Power Switch, Control Switch, and Dispense Mode Switch ........15 1.
  • Page 4 IV. Service Diagnosis ......................21 A. Ice Production Check ....................21 B. Diagnostic Procedure ....................21 C. Control Board Check ....................26 D. Bin Control Check ....................... 31 E. Float Switch Check and Cleaning ................32 1. Float Switch Check ....................32 2.

  • Page 5: Important Safety Information

    Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury.
  • Page 6 NOTICE • Follow the instructions in this manual carefully to reduce the risk of costly water damage. • In areas where water damage is a concern, install in a contained area with a floor drain. • Install the icemaker in a location that stays above freezing. Normal operating ambient temperature must be within 45°F to 100°F (7°C to 38°C). • Do not leave the icemaker on during extended periods of non-use, extended absences, or in sub-freezing temperatures. To properly prepare the icemaker for these occasions, follow the instructions in "VI.C. Preparing the Icemaker for Periods of Non-Use."...

  • Page 7: Specifications

    I. Specifications A. Icemaker 1. DCM-300BAH(-OS) AC SUPPLY VOLTAGE 115-120/60/1 COMPRESSOR 115 V 6.0 RLA 29 LRA GEAR MOTOR 120 V 1.45 FLA 80 W FAN MOTOR 115 V 0.8 FLA 16 W AGITATING MOTOR 115 V 0.9 FLA 55 W...

  • Page 8: General Information

    II. General Information A. Construction 1. Icemaker Thermostatic Expansion Valve Spout A Spout B Bin Control Actuator Evaporator Assembly Bin Control Proximity Switch Inlet Water Valve Storage Bin Float Switch Reservoir Agitator Control Box Power Switch Ice Dispense Auger Gear Motor CONTROL 4A1038-014 Agitating Motor...

  • Page 9: Icemaking Unit

    2. Icemaking Unit Cutter Extruding Head and Upper Bearing Seal Bolts and Washers Auger Evaporator Socket Head Cap Screw Mechanical Seal and Split Lock Washer Housing and Lower O-Ring Bearing Spline Coupling Hex Bolt and Washer Gear Motor Socket Head Cap Screw and Split Lock Washer...

  • Page 10: Sequence Of Operation

    B. Sequence of Operation 1. Sequence Cycles and Shutdown The steps in the sequence are as outlined below. When power is supplied, power switch is in the "ON" position, safety switch is engaged, and the control switch is in the "ICE" position, CB "POWER"...

  • Page 11: Sequence Flow Chart

    2. Sequence Flow Chart...

  • Page 12: Control Board

    C. Control Board • A Hoshizaki exclusive control board is employed in Hoshizaki icemakers. • All models are pre-tested and factory adjusted. • For a control board check procedure, see "IV.C. Control Board Check Procedure." NOTICE • The control board is fragile; handle very carefully. • The control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the icemaker before handling or replacing the control board.

  • Page 13: Control Board Layout

    1. Control Board Layout a) DCM-300BAH "DCM-PB" Push Button Model Control Board • Ice Dispense Time Control • Counter Reset Button (not used in this application) • Relay LEDs (red) • "FLUSH" (drain) Switch (indicate which relays (Do not adjust) and connector pins are • K3 Connector...

  • Page 14: B) Dcm-300Bah-Os

    DCM-300BAH-OS "DCM-OS" Opti-Serve Model Control Board • Relay LEDs (red) (indicate which relays and connector pins are • Ice Dispense Time Control energized) • "FLUSH" (drain) LED (X6 Relay) • K3 Connector K2 Connector Pin #10 #3 24VAC Output to 12-hr.

  • Page 15: Led Lights And Components

    DispWV (Opti-Serve Only) Legend: AM–agitating motor; Comp–compressor; DispWV–dispense water valve ("WTR" LED on DCM-300BAH-OS); DM–dispense motor; DS–dispense solenoid; DV–drain valve; FM–fan motor; GM–gear motor; WV–inlet water valve D. Power Switch, Control Switch, and Dispense Mode Switch The power switch, control switch, and dispense mode switch are used to control the operation of this icemaker.

  • Page 16: Control Switch

    2. Control Switch The control switch is a double-pole double-throw switch with 3 positions, "ICE," "OFF," and "DRAIN." a) ICE When the control switch is in the "ICE" position, the control switch directs 5VDC from control board K4 connector pin #3 to control board K4 connector pin #4. When the control board receives 5VDC on K4 connector pin #4, the icemaking process starts.

  • Page 17: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit Inlet Spout Water Valve Water Supply Float Switch Water Level Reservoir Evaporator Overflow Drier Expansion Valve To Drain Drain Valve Gear Motor Dispense Water Valve Fan Motor Condenser High-Pressure Switch Access Access Compressor Valve...

  • Page 18: Wiring Diagrams

    B. Wiring Diagrams 1. DCM-300BAH * High-Pressure Switch 412± PSIG Cut-out 327±21 PSIG Cut-in...

  • Page 19: Dcm-300Bah-Os

    2. DCM-300BAH-OS * High-Pressure Switch 412± PSIG Cut-out 327±21 PSIG Cut-in...

  • Page 20: Performance Data

    C. Performance Data 1. DCM-300BAH(-OS) APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F) PER 24 HR. lbs./day kg/day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. gal./day l/day EVAPORATOR OUTLET TEMP °F °C HEAD PRESSURE 14.1 14.1 14.1...

  • Page 21: Service Diagnosis

    IV. Service Diagnosis WARNING • This icemaker should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Risk of electric shock. Use extreme caution and exercise safe electrical practices. • Moving parts (e.g., fan blade) can crush and cut. Keep hands clear. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced. Make sure that none have fallen into the storage bin.
  • Page 22 7) Startup – Move the power switch to the "ON" position, then move the control switch to the "ICE" position to start the automatic icemaking process. Diagnosis: Check that CB "POWER" LED is on. If not, check for proper power supply voltage (115VAC) input to CT.
  • Page 23 9) Ice Purge Cycle – "GM" LED is on. GM and GMPR energize. 60-sec. ice purge timer starts. GM runs for 60 sec. to clear any ice from the evaporator. Note: GM cannot energize unless UF/S is closed, WCR is energized, and WCR terminals #4 (O wire) and #6 (GY wire) are closed.
  • Page 24 12) Drain Cycle – "FLUSH" (drain) LED is on. The icemaker drains the evaporator and reservoir once every 12 hr. A manual drain is provided when cleaning the icemaker by moving the control switch from the "ICE" position to the "DRAIN" position. a) Automatic Drain Cycle: A drain cycle occurs once every 12 hr.
  • Page 25 if defective. If 24VAC is present, check for 24VAC at GMPR terminal #2 (P wire) to a neutral (LBU wire). If 24VAC is not present, check GMPR continuity between terminals #2 (P wire) and #6 (LBU wire). If open, replace GMPR. Next, check for 24VAC at DV.

  • Page 26: Control Board Check

    C. Control Board Check Before replacing CB that does not show a visible defect and that you suspect is bad, conduct the following CB check. This procedure will help you verify your diagnosis. Before proceeding, check for proper voltage per unit nameplate. Check that the 24VAC 1A fuse, 10.5VAC 0.5A CT fuse are good, and the 115VAC GM external protector is not tripped.
  • Page 27 • Icemaking Control Circuit: The icemaking control circuit consists of WCR, CS, and BC. The icemaking control circuit activates once UF/S closes. Once CB reads a closed circuit through WCR, CS, and BC, CB then starts the 60-sec. ice purge cycle (GM operation). Once UF/S closes, WCR energizes, closing contacts between WCR terminals #4 (GY wire) and #6 (O wire).
  • Page 28 b) Opti-Serve Model – "ICE" and "AM" LEDs are on: (1) "CONTINUOUS" Mode: Before engaging the ice dispense Opti-Serve sensor, check for 5VDC from the locations given in the table below. If VDC is different than in the table, replace CB. If VDC is correct, engage the Opti-Serve sensor and confirm that VDC matches the table below.
  • Page 29 • Water Dispense Switch/Water Dispense Sensor a) Push Button Model: The water dispense button and DispWV are not associated with CB. Engage the water dispense button, then check for 24VAC at DispWV. If 24VAC is present and no water is dispensed, check for water supply line shut-off valve closed, clogged water filters, clogged WV screen.
  • Page 30 8) Drain Cycle – "FLUSH" (drain) LED is on: 12-hr. DCT terminates or CS is moved to "DRAIN" position. 150-sec. shutdown sequence starts. 90 seconds later, Comp de-energizes and Comp LED turns off. 60 seconds after Comp de-energizes, GM de-energizes and GM LED turns off. Drain cycle starts. "FLUSH" LED turns on and DV energizes.

  • Page 31: Bin Control Check

    D. Bin Control Check 1) Remove the front and top panels. 2) Remove the storage bin cover. If necessary, dispense ice so that the BC actuator is not engaged or remove the ice manually. WARNING! Care should be taken to avoid the agitator during BC testing.

  • Page 32: Float Switch Check And Cleaning

    E. Float Switch Check and Cleaning 1. Float Switch Check 1) Remove the front panel, then make sure the power switch is in the "ON" position. 2) Move the control switch to the "DRAIN" position. 3) Engage the safety switch and allow the evaporator and reservoir to drain. 4) Disengage the safety switch, then move the power switch to the "OFF"...

  • Page 33: Float Switch Cleaning

    3) Turn off the power supply. 4) Remove F/S assembly from the reservoir cover. See Fig. 1. 5) Wipe down F/S assembly with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Rinse the assembly thoroughly with clean water.

  • Page 34: Diagnostic Charts

    F. Diagnostic Charts Before consulting the diagnostic charts, check for correct installation, proper voltage per unit nameplate, and adequate water pressure (10 to 113 PSIG). Check CB using the steps in "IV.C. Control Board Check." 1. No Ice Production Startup 1.
  • Page 35 Ice Purge Cycle 1. Control Board a) No power to gear motor. 2. Gear Motor a) External protector (gear motor overload) open. b) Internal protector open. c) Motor winding open. d) Mechanical failure. 3. Coupling a) Defective. Freeze Cycle 1. Control Board a) Defective.
  • Page 36 2. Ice/Water Dispense Ice Dispense Push Button 1. Power Supply a) See "Startup." 2. Control Board a) Ice dispense switch circuit open or no power. b) No power to ice dispense solenoid, ice dispense motor, or agitating motor. 3. Ice Dispense Switch a) Defective.
  • Page 37 3. Opti-Serve (OS) Sensors Be sure to check all items in section "IV.F.2. Ice/Water Dispense" prior to using this chart. Use the following charts along with the wiring diagram to troubleshoot the OS sensors. Ice Sensor 1. OS Sensor a) Dirty. b) Defective.

  • Page 38: Removal And Replacement Of Components

    V. Removal and Replacement of Components WARNING • This icemaker should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Move the power switch to the "OFF" position and turn off the power supply to the icemaker before servicing. Lockout/Tagout to prevent the power from being turned back on inadvertently. • CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the equipment is serviced.

  • Page 39: Refrigerant Recovery

    1. Refrigerant Recovery This icemaker is provided with refrigerant access valves. Using proper refrigerant practices, recover the refrigerant from the service valves and store it in an approved container. Do not discharge the refrigerant into the atmosphere. 2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C).

  • Page 40: Important Notes For Component Replacement

    Remember to loosen the connection and purge the air from the hose. See the rating label inside the icemaker for the required refrigerant charge. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used.

  • Page 41: Evaporator Assembly

    Evaporator Assembly Spout A Evaporator Assembly Cutter Spout B Extruding Head and Power Switch Upper Bearing Auger Control Switch Dispense Mode Switch Washer Allen Head Cap Screw Evaporator Allen Head Cap Screw with Washer Mechanical Seal Ring Housing and O-Ring Lower Bearing Hex Head Bolt with Washer...

  • Page 42: 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 .02", follow the instructions below. See Fig. 3. 1) Move the control switch to the "OFF" position, then turn off the power supply. Remove the front and top panels, then move the power switch to the "OFF"...

  • Page 43: Removal And Replacement Of Auger

    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"...
  • Page 44 3) Remove the apron panel, then remove the left side panel. 4) Recover the refrigerant and store it in an approved container. 5) Remove the front cover of the storage bin. Remove spout B, then remove spout A. See Fig. 2. 6) Remove the allen head cap screws securing the extruding head.

  • Page 45: Removal And Replacement Of Mechanical Seal And Lower Housing

    5. Removal and Replacement of Mechanical Seal and Lower Housing 5a. Mechanical Seal 1) Move the control switch to the "DRAIN" position and drain all of the water from the evaporator. 2) After the water has stopped draining, move the control switch to the "OFF" position, then turn off the power supply.

  • Page 46: Removal And Replacement Of Gear Motor

    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.

  • Page 47: Dispense Auger And Agitator

    7. Dispense Auger and Agitator 1) Move the control switch to the "OFF" position, then turn off the power supply. Remove the front and top panels, then move the power switch to the "OFF" position. 2) Remove the front cover of the storage bin. 3) Remove the thumbscrews from the vertical plane, then loosen the thumbscrews from the horizontal plane of the motor bracket.

  • Page 48: Cleaning And Maintenance

    Consult with your local distributor about cleaning and maintenance service. To obtain the name and phone number of your local distributor, visit www.hoshizaki.com or call Hoshizaki Technical Support at 1-800-233-1940 in the USA.

  • Page 49: Cleaning And Sanitizing Instructions

    A. Cleaning and Sanitizing Instructions Hoshizaki recommends cleaning and sanitizing this icemaker at least twice a year. More frequent cleaning and sanitizing, however, may be required in some existing water conditions. WARNING • To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners. • Carefully follow any instructions provided with the bottles of cleaning and sanitizing solution. • Always wear liquid-proof gloves and goggles to prevent the cleaning and sanitizing solutions from coming into contact with skin or eyes.

  • Page 50: C) Sanitizing Solution

    9) In bad or severe water conditions, clean the float switch assembly as described below. Otherwise, continue to step 10. a. Remove the float switch assembly from the reservoir cover. b. Wipe down the float switch assembly with the cleaning solution. c. Rinse the float switch assembly thoroughly with clean water. d. Replace the float switch assembly in its correct position. 10) Move the power switch to the "ON" position and replace the panels in their correct positions. 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.

  • Page 51: Dispense Components

    2. Dispense Components Perform after cleaning and sanitizing the water system as outlined above. a) Cleaning Solution Dilute 9.6 fl. oz. (0.29 l) of Hoshizaki "Scale Away" with 1.6 gal. (6.0 l) 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 l) of warm water. c) Cleaning and Sanitizing Procedure 1) Move the control switch to the "OFF"...
  • Page 52 8) Remove the spout cover, ice dispense spout, and water dispense nozzle. See Fig. 7. 9) Immerse the agitator, dispense auger, and parts removed in steps 5 through 8 in the cleaning solution and then in the sanitizing solution for 15 minutes each. Rinse the parts thoroughly with clean water.

  • Page 53: Maintenance

    B. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the icemaker's environment, and local sanitation regulations. WARNING • Only qualified service technicians should service this icemaker. • Move the control switch and the power switch to the "OFF" position and turn off the power supply before servicing. Lockout/Tagout to prevent the power supply from being turned back on inadvertently. Maintenance Schedule Frequency Area Task Every 2 Air Filter...

  • Page 54: Preparing The Icemaker For Periods Of Non-Use

    C. Preparing the Icemaker for Periods of Non-Use NOTICE When storing the icemaker for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. When the icemaker is not used for two or three days under normal conditions, it is sufficient to only move the control switch to the "OFF"...

  • Page 55: Disposal

    VII. Disposal This icemaker contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.

This manual is also suitable for:

Dcm-300bah-os

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