Hoshizaki REFRIGERATED PREP TABLE WITH RAISED RAIL 73168 Service Manual
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Hoshizaki REFRIGERATED PREP TABLE WITH RAISED RAIL 73168 Service Manual

Hoshizaki REFRIGERATED PREP TABLE WITH RAISED RAIL 73168 Service Manual

Refrigerated prep table with raised rail
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Commercial Kitchen Equipment
Model
Refrigerated Prep Table with Raised Rail
SERVICE MANUAL
Number: 73168
Issued: 8-12-2009
Revised: 5-11-2011

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Summary of Contents for Hoshizaki REFRIGERATED PREP TABLE WITH RAISED RAIL 73168

  • Page 1 Hoshizaki America, Inc. “A Superior Degree of Reliability” www.hoshizaki.com Commercial Kitchen Equipment Model Refrigerated Prep Table with Raised Rail SERVICE MANUAL Number: 73168 Issued: 8-12-2009 Revised: 5-11-2011...
  • Page 2 Hoshizaki provides this manual primarily to assist qualified service technicians in the service and maintenance of the unit. 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

    This manual should be read carefully before the unit is serviced or maintenance operations are performed. Only qualified service technicians should install, service, and maintain the unit. 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.
  • Page 4 III. Service Diagnosis ... 25 A. Alarm Signals ... 25 1. High Temperature Alarm (E1) ... 27 2. Low Temperature Alarm (E2) ... 28 3. Cabinet Defrost Alarm (E3) ... 29 4. High Condenser Temperature Alarm (clogged filter) (E7) ... 30 5.
  • Page 5 5. Door/Drawer Gaskets ... 59 6. Shelves (if applicable) ... 59 7. Drawers (if applicable) ... 59 B. Maintenance ... 60 1. Rail Condensate Pan ... 60 2. Air Filter... 60 3. Condenser ... 60 4. Power Supply Connection ... 60 C.

  • Page 6: Important Safety Information

    Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, or damage to the unit. WARNING Indicates a hazardous situation which could result in death or serious injury. CAUTION Indicates a situation which could result in damage to the unit.

  • Page 7: Specifications

    I. Specifications A. Nameplate Ratings Model AC Supply Voltage HPR46A(-D) HPR72A 115/60/1 HPR72A-D HPR100A(-D) B. Dimensions Rail Interior Capacity Volume QTY of 1/6 Model Cu. Ft. Sized Pans HPR46A(-D) (1 Section) HPR72A(-D) 18.8 (2 Section) HPR100A(-D) 29.1 (3 Section) Door Opening Opening Height...

  • Page 8: General Information

    II. General Information A. Construction This Hoshizaki unit features a cartridge-type refrigeration system that can be removed (excluding the rail evaporator). Rail Cover Rail Fan Motors and Fan Shrouds Compressor Side Panel Receiver Tank Condenser Fan Motor Cabinet Evaporator Fan Motors...

  • Page 9: Sequence Of Operation

    B. Sequence of Operation The steps in the sequence are as outlined below. 1. Startup When the power switch is in the "ON" position, the cabinet temperature is displayed and cabinet cooling begins. When the power switch is in the "ON" position and the rail cooling switch is moved to the "NORMAL" or "LOW" position, the rail temperature is displayed and rail cooling begins. The "NORMAL" rail switch position is designed for use when the rail cover is open. The "LOW" rail switch position is designed for use when the rail cover is closed. For further details, see "II.D.4.a) Switch Settings." a) Power Switch "ON," Rail Cooling Switch "OFF" Cabinet temperature at or above setpoint: CabFM, CLLV, and PH energize. The 2 minute Comp delay timer and 6 hour DT start.

  • Page 10: Cool Down Restart

    (3) Both CTh and RTh reach 3.6°F (2°C) below setpoint CabFM and PH continue. RailFM continues when rail cooling switch is in the "NORMAL" position and per F9 setting when in the "LOW" position. For details, see "II.D.4.a) Switch Settings." Comp, ConFM, and CLLV de‑energize. RLLV de-energizes for 2 seconds. RLLV energizes, then remains energized during Comp off time. 4. Cool Down Restart a) Power Switch "ON,"...

  • Page 11: Rail Defrost

    a) Cabinet Defrost: Power Switch "ON," Rail Cooling Switch "OFF" CLLV continues, CabFM, Comp, ConFM, and PH de-energize. DH energizes and warms DTh to 49°F (9.4°C) (or the 100-minute defrost termination timer expires or DTst warms to 120°F±5°F (49°C±3°C)). When DTh reaches 49°F (9.4°C), DH de-energizes, CLLV continues and a 5 minute Comp delay timer starts.

  • Page 12: Sequence Of Operation Charts

    C. Sequence of Operation Charts 1. Cabinet Cooling setpoint warms...

  • Page 13: Cabinet And Rail Cooling

    2. Cabinet and Rail Cooling setpoint warms...
  • Page 14 2. Cabinet and Rail Cooling (continued)

  • Page 15: Control Board

    D. Control Board • A Hoshizaki exclusive solid‑state control board is employed in all Hoshizaki HPR46A(-D), HPR72A(-D), and HPR100A(-D) units. • All models are pretested and factory set. 1. The control board is fragile; handle very carefully. 2. 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 unit when handling or replacing the control board.

  • Page 16: Control Board Layout

    2. Control Board Layout Display/Change Rail Setpoint Rail Temperature, Alarm Display, and Service Menu LED on for Negative Values K341 Connector # 1, 2 Rail Fan Relay (Orange) K101 Connector # 1, 3 Transformer 10V Control Voltage (Dark Blue) K151 Connector # 1, 2 Condenser Thermistor (Gray) (Clogged Filter Thermistor)

  • Page 17: Features

    3. Features a) LED Display and Service Lock-Out This control board uses twin LED displays to show system details and diagnostic information. For control board voltage protection, a 3A 125V fuse is incorporated into the control board circuitry. A service jumper is also provided to protect against unwanted changes to the unit's settings.

  • Page 18: Controls And Adjustments

    The rail fans operate intermittently when "F9" is at the factory default setting. For access and adjustments to the "F9" setting, see "II.D.5. Service Menu." Note: A Hoshizaki OEM rail cooling switch must be used if replacing the rail cooling switch. For details see "IV.M. Rail Cooling Switch." b) Temperature Display The temperature display can be changed between Fahrenheit and Celsius. To change the temperature display, press and hold the cabinet "SET" button and the "SERVICE...

  • Page 19: C) Temperature Setpoint

    c) Temperature Setpoint The temperature setpoint is the temperature setting at which the compressor turns on. The factory default temperature setpoints are 37° (3°C) for the cabinet and 33°F (1°C) for the rail (see the chart below). The temperature differential for the compressor to turn off is 3.6°F (2°C) below the temperature setpoint.

  • Page 20: F) Temperature Correction Factor

    Negative values are indicated by an LED to the left of the value (Decimals are not shown on display) If it is determined through discussion with Hoshizaki Technical Support that the setting needs to be changed, follow the steps below.

  • Page 21: Service Menu

    5. Service Menu The service menu ("F0" to "F9") may be used to change settings, acquire diagnostic information, and to view alarm history. To access the "F0" through "F9" service menu selections, you must first disconnect the service jumper (excluding "F5" which is accessible with or without the service jumper in place). The service jumper is located behind the wire cover below the control box and connects the control board K151 connector terminals 7 and 8 (white) together. When the service jumper is in place, only the "F5" selection is accessible. Be sure to reconnect the service jumper when finished.

  • Page 22: B) Service Menu Chart

    • Initiating a manual defrost on the cabinet will restart the defrost timer. Defrost Termination Temperature Do not adjust. For recommendations, contact Hoshizaki Technical Support. Setpoint Temperature Differential Use "SET" button to scroll through all 4 settings. • You cannot set both + and ‑ to 0.0. • Negative value indicated by LED to left of number.

  • Page 23: Alarm Signals

    6. Alarm Signals In the event of operation outside of normal parameters, the control board identifies the issue with an alarm signal. The alarm signal and temperature are displayed in 1-second intervals. For service corrections, see "III.A. Alarm Signals." 7. Control Board Check Procedure Before replacing a control board that does not show a visible defect and that you suspect is bad, always conduct the following check procedure.

  • Page 24: Thermistor Check

    E. Thermistor Check Thermistors (semiconductors) are used for temperature control in the cabinet and rail areas, defrost termination, and for monitoring condenser temperature (clogged filter). The resistance varies depending on temperature. No adjustment is required. If necessary, check for resistance between thermistor leads and visually check the thermistor mounting.

  • Page 25: Service Diagnosis

    III. Service Diagnosis 1. This unit should be disassembled or repaired only by a qualified service technician to reduce the risk of injury, electric shock, or fire. 2. Do not make any alterations to the unit. This could cause water leak, electric shock, or fire.
  • Page 26 Alarm Priority Problem Signal High Condenser Temperature Alarm (clogged filter) Condenser temperature is outside of normal operating temperature. 140°F (60°C) Defrost Thermistor Malfunction Alarm Defrost thermistor shorted or open. Condenser Thermistor Malfunction Alarm Condenser thermistor shorted or open. EEPROM Write Alarm Control board has failed.

  • Page 27: High Temperature Alarm (E1)

    1. High Temperature Alarm (E1) If the cabinet or rail temperature exceeds the setpoint temperature by 18°F (10°C) or more for more than x hours, "E1" is displayed. The default value of x is "2" (2 hours). The value of x can be changed under "F3" on the service menu. (0=No delay; 1=1; 2=2; 3=3 hours) Note: • After the machine has been turned off and then turned back on, the high temperature alarm feature is not active until the area temperature reaches the lower setpoint temperature differential. • The high temperature alarm feature operates even during defrost.

  • Page 28: Low Temperature Alarm (E2)

    2. Low Temperature Alarm (E2) If the cabinet or rail temperature drops below the setpoint temperature by 9°F (5°C) or more for more than y hours, "E2" is displayed. The default value of y is "1" (1 hour). The value of y can be changed under "F4" on the service menu. (0=No delay; 1=1 hour) Note: • The low temperature alarm timer starts once the cabinet temperature drops 9°F (5°C) below the setpoint temperature. • The low temperature alarm feature operates even during defrost. Reset Options The alarm will automatically reset once the area temperature reaches the upper setpoint temperature differential.

  • Page 29: Cabinet Defrost Alarm (E3)

    3. Cabinet Defrost Alarm (E3) Once the defrost termination temperature is reached, the signal from the defrost thermistor should terminate the defrost. If the defrost thermistor does not terminate the defrost within 100 minutes (1 hour and 40 minutes), "E3" is displayed. When "E3" is displayed, the next step in the defrost process begins. Reset Options To reset the alarm, turn the power off and then back on.

  • Page 30: High Condenser Temperature Alarm (Clogged Filter) (E7)

    4. High Condenser Temperature Alarm (clogged filter) (E7) The unit is equipped with a condenser air filter to protect the condenser from dirt, grease, etc. The condenser air filter promotes clean condenser surfaces and efficient operation and should be checked twice monthly and cleaned when necessary. The unit is also equipped with a condenser thermistor to determine if the condenser or condenser air filter is excessively dirty.

  • Page 31: Defrost Thermistor (Cabinet) Malfunction Alarm (E8)

    5. Defrost Thermistor (cabinet) Malfunction Alarm (E8) If the control board detects an open defrost thermistor, "E8" is displayed. When the control board detects a shorted defrost thermistor, a 10-minute delay timer begins. After the 10‑minute delay timer expires, "E8" is displayed. To bypass the 10‑minute delay timer, move the power switch to the "OFF" position. Then, while pressing the rail "SET" button, move the power switch to the "ON" position. • If this alarm appears, first make sure that the thermistor is properly connected to the control board. • A shorted defrost thermistor is not detected by the control board during the 1st hour after power is turned on. To bypass the 1-hour delay timer, move the power switch to the "OFF" position. Then, while pressing the rail "SET" button, move the power switch to the "ON" position.

  • Page 32: Condenser Thermistor Malfunction Alarm (E9)

    6. Condenser Thermistor Malfunction Alarm (E9) If the control board detects an open condenser thermistor, "E9" is displayed. When the control board detects a shorted condenser thermistor, a 10-minute delay timer begins. After the 10‑minute delay timer expires, "E9" is displayed. To bypass the 10‑minute delay timer, move the power switch to the "OFF" position. Then, while pressing the rail "SET" button, move the power switch to the "ON" position. • If this alarm appears, first make sure that the thermistor is properly connected to the control board. • A shorted condenser thermistor is not detected by the control board during the 1st hour after power is turned on. To bypass the 1-hour delay timer, move the power switch to the "OFF" position. Then, while pressing the rail "SET" button, move the power switch to the "ON" position.

  • Page 33: Control Board Alarms (Ea And Ed)

    7. Control Board Alarms (EA and ED) "EA" is displayed when an EEPROM write error is detected. "ED" is displayed when an EEPROM verification or read error is detected. Reset Options Replacing the control board with a functioning control board will eliminate this alarm condition. B. Service Chart 1. No Operation Problem Possible Cause [1] The unit will not a) Power Supply start.

  • Page 34: Cabinet Cooling

    Problem Possible Cause [3] Compressor will f) Voltage not start or stops operating. g) High Pressure Switch (continued) g) High Pressure Switch (continued) h) Thermistors (cabinet and rail) i) Compressor Overload j) Compressor k) Control Board 2. Cabinet Cooling Problem Possible Cause [1] Cabinet a) Warm Food...
  • Page 35 See "II.D.4.c) Temperature Setpoint" or "II.D.4.f) Temperature Correction Factor" for defaults. 1. Frozen food recently 1. Allow time for unit to return placed in refrigerator. to setpoint temperature. 1. Defective. 1. Check and replace. 1. Does not close. 1. Check and replace. 1. Defective; contacts 1. Replace.

  • Page 36: Rail Cooling

    See "II.D.4.c) Temperature Setpoint" or "II.D.4.f)Temperature Correction Factor" for defaults. 1. Frozen food recently 1. Allow time for unit to return placed in refrigerator. to setpoint temperature. 1. Defective. 1. Check and replace. 1. Does not close. 1. Check and replace. 1. Defective. 1. Check and replace.

  • Page 37: Cabinet Defrost

    4. Cabinet Defrost Problem Possible Cause [1] Cabinet fan motors a) Cabinet Fan Relay b) Control Board [2] Evaporator does a) Defrost Thermistor not defrost completely. b) Defrost c) Defrost Heater d) Defrost Thermostat e) Cabinet Liquid Line Valve [3] Defrost cycle too a) Defrost long.

  • Page 38: Other

    5. Other Problem Possible Cause [1] Condensate a) Cabinet Contents water overflow. b) Location of Unit c) Seals d) Environment e) Rail Condensate Pan [2] Abnormal Noise a) Fasteners b) Compressor c) Fan d) Relay e) Liquid Line Valve Solenoid Remedy 1.

  • Page 39: Removal And Replacement Of Components

    IV. Removal and Replacement of Components 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Move the power switch to the "OFF" position and unplug the unit before servicing. 3. Make sure all food zones are clean after the unit is serviced. For cleaning procedures, see "V. Cleaning and Maintenance Instructions."...

  • Page 40: Brazing

    2. Brazing 1. R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). 2. R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), these refrigerants can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous.
  • Page 41 5) Turn off the vacuum pump. Disconnect the vacuum pump hose and attach it to a refrigerant service cylinder. 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 42: Removal And Replacement Of Refrigeration System Cartridge

    B. Removal and Replacement of Refrigeration System Cartridge The refrigeration system cartridge should not be removed until the refrigerant has been properly recovered or the refrigeration system has been properly pumped down. For refrigeration system repairs, the refrigerant recovery procedure must be used. See "IV.B.1. Refrigerant Recovery Procedure." For non‑refrigeration system repairs, see "IV.B.2. Pump‑Down Procedure." Do not discharge the refrigerant into the atmosphere.
  • Page 43 13) Slide the refrigeration cartridge forward. Support the evaporator as it clears the evaporator case. See Fig. 2. 1. Be careful when handling the cabinet evaporator assembly. This assembly includes a defrost heater sheathed in a glass tube. This sheathing can be easily damaged and may also cause cuts if broken.

  • Page 44: Refrigeration System Pump-Down Procedure

    2. Refrigeration System Pump-Down Procedure 1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the unit. 2) Remove the left side panel. 3) Connect the gauge manifold hoses to the receiver service valve (high-side) and the rail low-side access valve. See Fig. 1. Note: Be sure the high-side gauge manifold hose is on the receiver service valve before opening the receiver service valve.
  • Page 45 16) Once the repair is made, replace the refrigeration cartridge back into its correct position. Support the cabinet evaporator as it enters the cabinet evaporator case. 17) Reconnect the rail side refrigerant tubes. Use a backup wrench and tighten the fittings 1/6 turn beyond fully seated.

  • Page 47: Removal And Replacement Of Compressor

    C. Removal and Replacement of Compressor 1. Always install a new drier every time the sealed refrigeration system is opened. 2. 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.

  • Page 48: Removal And Replacement Of Cabinet Evaporator

    15) Replace the panels in their correct positions. 16) Plug in the unit, then move the power switch to the "ON" position to start the unit's cooling process. D. Removal and Replacement of Cabinet Evaporator 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made.

  • Page 49: Removal And Replacement Of Expansion Valve

    8) Braze the fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG. 9) Replace the removed evaporator parts in their correct positions. 10) Once the repair is complete, return to step 15 in "IV.B.1. Recovery Procedure" for refrigeration system cartridge replacement. E. Removal and Replacement of Expansion Valve Moisture in the refrigeration circuit may exceed drier capacity and freeze up at the expansion valve.

  • Page 50: Removal And Replacement Of Liquid Line Valve

    F. Removal and Replacement of Liquid Line Valve 1. Always install a new drier every time the sealed refrigeration system is opened. 2. 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.

  • Page 51: Removal And Replacement Of Condenser

    G. Removal and Replacement of Condenser 1. Always install a new drier every time the sealed refrigeration system is opened. 2. 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.

  • Page 52: Removal And Replacement Of Thermistors And Thermostat

    H. Removal and Replacement of Thermistors and Thermostat 1. The thermistors are fragile; handle very carefully. 2. Do not shorten or cut the thermistor leads. 1. Cabinet Thermistor 1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2. Pump‑Down Procedure." Once the refrigeration system cartridge is out, proceed to step 2. 2) Cut the cable tie holding the cabinet thermistor to the cabinet thermistor bracket. Remove the thermistor.

  • Page 53: Defrost Thermostat

    3. Defrost Thermostat 1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2. Pump‑Down Procedure." Once the refrigeration system cartridge is out, proceed to step 2. 2) Disconnect the defrost thermostat wires, then remove the defrost thermostat. See Fig. 5. 3) Install the new defrost thermostat and connect the thermostat wires. 4) Once the repair is complete, return to step 17 in "IV.B.2. Pump‑Down Procedure" for refrigeration system cartridge replacement. 4. Rail Thermistor 1) Open the front panel. Move the power switch to the "OFF" position, then unplug the unit.

  • Page 54: Condenser Thermistor (Clogged Filter)

    5. Condenser Thermistor (clogged filter) 1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the unit. 2) Remove the left side panel. 3) Remove the aluminum tape and cut the cable tie securing the thermistor. See Fig. 7. 4) Remove the thermistor. Disconnect the wire connection (below the control box). 5) Install the new thermistor and secure with a cable tie and aluminum tape.

  • Page 55: Removal And Replacement Of Fan Motors

    J. Removal and Replacement of Fan Motors 1. Cabinet Fan Motor Be careful when handling the evaporator shroud assembly. This assembly includes a defrost heater sheathed in a glass tube. This sheathing can be easily damaged and may also cause cuts if broken. Heater will also be hot after a defrost.

  • Page 56: Condenser Fan Motor

    2. Condenser Fan Motor 1) Open the front panel. Move the power switch to the "OFF" position, then unplug the unit. 2) Remove the left side panel. 3) Disconnect the fan motor wires. 4) Remove the condenser fan motor assembly bolts, then remove the condenser fan motor assembly. See Fig. 10. 5) Remove the fan motor from the fan motor bracket and remove the fan blade from the fan motor.

  • Page 57: Removal And Replacement Of Door Gasket

    In order to get a proper gasket fit, it is important not to stretch gasket material during assembly. L. Door Re-Hinging and Drawer Conversion Contact your local Hoshizaki distributor or Hoshizaki Technical Support if door reversing or drawer conversion is desired. Rail Fan Motor...

  • Page 58: Cleaning And Maintenance Instructions

    2. Before cleaning the unit, move all foods into another clean refrigerator or freezer. 3. Do not splash water directly onto the unit. This might cause short circuit, electric shock, corrosion, or failure.

  • Page 59: Rail And Rail Cover

    2. Rail and Rail Cover Spills and splashes should be wiped up promptly to avoid unpleasant odors. Wipe the interior of the rail and the rail cover regularly with a clean, damp sponge or cloth containing a neutral cleaner. Do not pour or spray water into the rail area. 1.

  • Page 60: Maintenance

    3) Replace the air filter in its proper position. 4. Power Supply Connection If the plug or power cord is damaged, contact a Hoshizaki Certified Service Representative immediately and ask for repairs. All other maintenance or service on this unit should be performed in accordance with the Hoshizaki Service Manual by a qualified service technician.

  • Page 61: Shutdown And Long Storage

    5. Do not plug in/unplug the unit to start/stop operation. Make sure the power switch is in the "OFF" position before plugging in or unplugging the unit to help reduce the risk of electric shock. 1) Before shutting down the unit, move food into another refrigerator or freezer. 2) Open the front panel and move the power switch to the "OFF" position. The unit will shut down. 3) Unplug the unit.

  • Page 62: Technical Information

    VI. Technical Information A. Refrigeration Circuit 1. HPR46A(-D), HPR72A(-D), HPR100A(-D)

  • Page 63: Wiring Diagrams

    B. Wiring Diagrams 1. HPR46A(-D) Transformer Output 10V at 115V *High Pressure Switch Cut-out 490±10 PSIG Cut-in 370±20 PSIG...

  • Page 64: 2A. Hpr72A(-D) Auxiliary Code U-5 And Earlier

    2a. HPR72A(-D) Auxiliary Code U-5 and Earlier Transformer Output 10V at 115V *High Pressure Switch Cut-out 490±10 PSIG Cut-in 370±20 PSIG...

  • Page 65: 2B. Hpr72A(-D) Auxiliary Code U-6 And Later

    2b. HPR72A(-D) Auxiliary Code U-6 and Later Transformer Output 10V at 115V *High Pressure Switch Cut-out 490±10 PSIG Cut-in 370±20 PSIG...

  • Page 66: Hpr100A(-D)

    3. HPR100A(-D) AWAITING DATA...

This manual is also suitable for:

Hpr46aHpr46a-dHpr72aHpr72a-dHpr100aHpr100a-d

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