Hoshizaki DCM-240BAF Service Manual
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Hoshizaki DCM-240BAF Service Manual

Hoshizaki DCM-240BAF Service Manual

Cubelet ice dispenser
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NO.:
73067
ISSUED:
JUNE 23, 1998
REVISED:
DEC. 15, 2003
HOSHIZAKI
CUBELET ICE DISPENSER
MODEL
DCM-240BAF
SERVICE MANUAL

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Summary of Contents for Hoshizaki DCM-240BAF

  • Page 1 NO.: 73067 ISSUED: JUNE 23, 1998 REVISED: DEC. 15, 2003 HOSHIZAKI CUBELET ICE DISPENSER MODEL DCM-240BAF SERVICE MANUAL...
  • Page 2 No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the dispenser. Should the reader have any questions or concerns which have not been satisfactorily addressed, please call or write to the HOSHIZAKI Technical Support Department for assistance.

  • Page 3: Table Of Contents

    This manual should be made available to the technician prior to service or maintenance. CONTENTS PAGE I. SPECIFICATIONS ......................5 1. DCM-240BAF (Air-cooled) ..................5 II. GENERAL INFORMATION ....................6 1. CONSTRUCTION ....................... 6 2. OPERATION - How it works ..................7 III. TECHNICAL INFORMATION ..................8 1.
  • Page 4 VI. CLEANING AND MAINTENANCE INSTRUCTIONS ............ 42 1. PREPARING THE ICE DISPENSER FOR LONG STORAGE ........42 2. CLEANING INSTRUCTIONS ..................44 [a] CLEANING PROCEDURE .................. 44 [b] SANITIZING PROCEDURE ................46 3. MAINTENANCE INSTRUCTIONS ................48...

  • Page 5: Specifications

    I. SPECIFICATIONS 1. DCM-240BAF (Air-cooled) AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.5 A [ AT 104°F (40°C) / WT 80°F (27°C) ] MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION Ambient Water Temp. (°F/°C) PER 24 HR. 50/10 70/21 90/32 Temp (°F/°C)

  • Page 6: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION Hoshizaki Cubelet Ice Dispenser, model DCM-240BAF includes Water Supply, Freezer, Condensing, Storage, Dispensing and Control Assemblies. Fig. 1 Note: *Adjustable Legs Minimum height - 4" Maximum height - 5.3" Do not adjust exceeding the above recommendation.

  • Page 7: Operation - How It Works

    2. OPERATION - How it works Water flows from the potable water source through the Water Supply Line Shut-off Valve, enters at the Water Inlet fitting and into the Water Reservoir. The Water Reservoir func- tions to maintain a constant water level inside the Freezer Assembly. Water from the Water Reservoir enters at the bottom of the Freezer.

  • Page 8: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT A2AAA0269804...

  • Page 9: Wiring Diagram

    2. WIRING DIAGRAM A2AAA0269804...

  • Page 10: Sequence Of Electrical Circuit

    3. SEQUENCE OF ELECTRICAL CIRCUIT POWER ON WATER STARTS TO BE SUPPLIED TO RESERVOIR AGITATION TIMER ON - (2 SEC.) A2AAA0269806...
  • Page 11 RESERVOIR FILLS UP GEAR MOTOR TURNS ON A2AAA0269806...
  • Page 12 COMPRESSOR STARTS @ 60 SEC. AFTER GEAR MOTOR A2AAA0269806...
  • Page 13 ICE MAKING CONTINUES A2AAA0269806...
  • Page 14 BIN CONTROL SWITCH TRIPPED COMPRESSOR STOPS @ 90 SEC. LATER A2AAA0269806...
  • Page 15 GEAR MOTOR STOPS @ 60 SEC. AFTER COMPRESSOR A2AAA0269806...
  • Page 16 DISPENSE ICE (BIN CONTROL STILL TRIPPED) A2AAA0269806...
  • Page 17 DISPENSE WATER (BIN CONTROL STILL TRIPPED) A2AAA0269806...
  • Page 18 WATER PRESSURE GETS LOW, BLACK AND BLUE LEADS OF FLOAT OPEN. COMPRESSOR STOPS @ 90 SEC. LATER AND GEAR MOTOR STOPS @ 60 SEC. AFTER COMPRESSOR STOPS. A2AAA0269806...
  • Page 19 FLUSH SWITCH ACTIVATED A2AAA0269806...
  • Page 20 FLUSH VALVE ACTIVATED WITH TIMER A2AAA0269806...
  • Page 21 AGITATION TIMER ACTIVATES GEAR MOTOR A2AAA0269806...

  • Page 22: Performance Data

    4. PERFORMANCE DATA AMBIENT WATER TEMP. ( °F/°C ) APPROXIMATE TEMP. ( °F/°C ) 50/10 70/21 90/32 ICE PRODUCTION PER 24 HR. 70/21 *275 ( 125 ) 265 ( 120 ) 250 ( 111 ) 80/27 240 ( 110 ) 230 ( 105 ) 215 ( 98 ) 90/32...

  • Page 23: Service Diagnosis

    IV. SERVICE DIAGNOSIS 1. NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] The ice a) Power Supply Cord 1) Broken or loose connection. 1) Check for continuity and dispenser will replace. b) Power Switch (on 1) “OFF” position. not start. 1) Move to “ON”...
  • Page 24 REMEDY PROBLEM POSSIBLE CAUSE a) Fan Motor 1) Replace. [5] Fan Motor 1) Motor winding opened. will not start. 2) Bearing worn out. 2) Replace. 3) Wiring to Fan Motor. 3) Check for loose connec- tion or open, and replace. 4) Fan blade bound.

  • Page 25: Low Ice Production

    Fan Motor. e) Inside wall of 1) Scale on inside wall of 1) Remove Auger, use Evaporator Freezing Cylinder. Hoshizaki “Scale Away” or “LIME-A-WAY” solution to clean periodically. If water is found to sur- pass the following levels, install a conditioner:...

  • Page 26: Faulty Dispenser

    3. FAULTY DISPENSER REMEDY PROBLEM POSSIBLE CAUSE a) Storage Bin 1) Ice block or bridge [1] No ice is 1) Remove all ice from dispensed. Storage Bin when not using ice dispenser for a long time. b) Agitator 1) Deformed due to ice block 1) Replace.

  • Page 27: Others

    4. OTHERS REMEDY PROBLEM POSSIBLE CAUSE a) Bin Control Switch 1) Contacts fused. [1] Ice dispenser 1) Replace. will not stop 2) Out of position. 2) Reinstall. even if filled b) Water Control Relay 1) Contacts fused. 1) Replace. c) Timer 1) Defective.

  • Page 28: Removal And Replacement Of Components

    REMOVAL AND REPLACEMENT OF COMPONENTS IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORTANT 1. 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 29: Brazing

    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.

  • Page 30: Removal And Replacement Of Compressor

    3. 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 re placement Compressor.

  • Page 31: Removal And Replacement Of Drier

    12) Braze the Process, Suction and Discharge lines (Do not change this order), while purging with nitrogen gas flowing at the pressure 3-4 PSIG. 13) Install the new Filter Drier. 14) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles. 15) Connect the Terminals, and replace the Terminal Cover in its correct position.

  • Page 32: Removal And Replacement Of Thermostatic Expansion Valve

    5. REMOVAL AND REPLACEMENT OF THERMOSTATIC EXPANSION VALVE IMPORTANT Sometimes moisture in the refrigerant 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 33: Removal And Replacement Of Pressure Switch

    13) Cover the Expansion Valve Bulb tightly with the insulation. 14) Place the new set of Expansion Valve Covers in position. 15) Replace the panels in their correct positions. 16) Plug in the dispenser and turn on the power supply. 6.

  • Page 34: Removal And Replacement Of Water Valve

    7. REMOVAL AND REPLACEMENT OF WATER VALVE 1) Turn off the power supply and unplug the dispenser. 2) Close the Water Supply Line Shut-off Valve. 3) Remove the Drain Cap and drain out. 4) Remove the panels. 5) Remove the valve outlet tubing by releasing the Clamp. 6) Remove the Fitting Nut and the Water Valve.

  • Page 35: Removal And Replacement Of Float Switch

    8. REMOVAL AND REPLACEMENT OF FLOAT SWITCH WARNING 1. Fragile, handle very carefully. 2. If the Float Switch works poorly because of scale or other foreign matter, install a filter or softener in the water supply line. 1) Unplug the dispenser and turn off the power supply. 2) Close the Water Supply Line Shut-off Valve.

  • Page 36: Removal And Replacement Of Bin Control Switch Assembly

    9. REMOVAL AND REPLACEMENT OF BIN CONTROL SWITCH ASSEMBLY 1) Turn off the power supply and unplug the dispenser. 2) Remove the Top Panel. 3) Remove the Storage Bin Cover. 4) Remove the Bin Control Switch. 5) Remove the Snap Pin and E-ring and disassemble the Balance Plate (A), Balance Plate (B) and Shaft.

  • Page 37: Removal And Replacement Of Storage Bin Assembly

    10. REMOVAL AND REPLACEMENT OF STORAGE BIN ASSEMBLY 1) Move the Ice Making Switch to the “OFF” position. 2) Press the Push Button to dispense ice and remove all ice from the Storage Bin. 3) Turn off the power supply and unplug the dispenser. 4) Remove the Drain Cap and drain out.

  • Page 38: Removal And Replacement Agitator And Drip Ring

    11. REMOVAL AND REPLACEMENT OF AGITATOR AND DRIP RING 1) Move the Ice Making Switch to the “OFF” position. 2) Press the Push Button to dispense ice and remove all ice from the Storage Bin. 3) Turn off the power supply, and unplug the dispenser. 4) Remove the Top Panel.

  • Page 39: Removal And Replacement Of Evaporator Assembly

    12. REMOVAL AND REPLACEMENT OF EVAPORATOR ASSEMBLY 1) Move the Ice Making Switch to the “OFF” position. 2) Press the Push Button to dispense ice and remove all ice from the Storage Bin. 3) Turn off the power supply, and unplug the dispenser. 4) Remove the Drain Cap and drain out.
  • Page 40 12) Remove the Insulation and the two Clamps on the Expansion Valve Bulb. 13) Disconnect the brazing-connections of the Expansion Valve and the Copper Tube - Low Side from the Evaporator, using brazing equipment. 14) Braze the new Evaporator with nitrogen gas flowing at the pressure of 3-4 PSIG. 15) Replace the Drier.
  • Page 41 GEAR MOTOR 24) Cut the Gear Motor leads at the wire connector. 25) Remove the three Hexagon Bolts securing the Gear Motor on the chassis. 26) Remove the Gear Motor. 27) Install the new Gear Motor. 28) Assemble the removed parts in the reverse order of which they were removed WARNING Be careful not to scratch the surface of the O-ring, or it may cause water leaks.

  • Page 42: Cleaning And Maintenance Instructions

    VI. CLEANING AND MAINTENANCE INSTRUCTIONS IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. PREPARING THE ICE DISPENSER FOR LONG STORAGE IMPORTANT When shutting off the ice dispenser for an extended time, drain out all water from the water line and remove the ice from the Storage Bin.
  • Page 43 4) Press the Push Button for ice dispensing, and remove all ice from the Storage Bin. 5) Wait until all water is drained out into Drain Pan and then turn Power Switch to the “OFF” Position. 6) Move Ice Switch to the “ON” position and unplug the ice dispenser. IMPORTANT Before operating the dispenser next time, check that the Drain Valve is closed, and open the Water Supply Line Shut-off Valve.

  • Page 44: Cleaning Instructions

    [a] CLEANING PROCEDURE 1) Close the Water Supply Line Shut-off Valve. 2) Dilute approximately 6 fl. oz. of the recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY,” (Economics Laboratory, Inc.) with 1 gal. of water. 3) Move the Ice Making Switch, located on the left of the Middle Front Panel, to the “FLUSH”...
  • Page 45 Middle Front Panel Spout (A) Thumbscrew Spout (B) Fig. 5 Fig. 6 A2AAA0269806...

  • Page 46: [B] Sanitizing Procedure

    10) Remove the Agitator and Drip Ring. See Fig. 6. 11) Pour the cleaning solution carefully into the Reservoir through the opening in the center of the Storage Bin up to the overflow level. (Overflowed solution can be seen in the Drain Pan.) 12) While waiting for 10 minutes to start icemaking process, wipe the Bin Liner and the Drip Plate using a clean cloth containing the cleaning solution.
  • Page 47 4) Move the Ice Making Switch to the “FLUSH” position. 5) Wipe the Bin Liner and the Drip Plate using a clean cloth containing the sanitizing solution. 6) Pour clean warm water carefully onto the Bin Liner and into the Reservoir through the opening in the center of the Storage Bin to melt the ice and rinse out the sanitizing solution.

  • Page 48: Maintenance Instructions

    2. MAINTENANCE INSTRUCTIONS IMPORTANT This ice dispenser must be maintained individually, referring to the instruction manual and labels provided with the ice dispenser. 1) Stainless Steel Exterior To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up.

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