DCM-500B Service Manual.pdf

Hoshizaki

“A Superior Degree of Reliability” www.hoshizaki.com

Models

DCM-500BAH

DCM-500BAH-OS

DCM-500BWH

DCM-500BWH-OS

Cubelet Icemaker / Dispenser

Hoshizaki America, Inc.

Number: 73165 Issued: 7-30-2008

SERVICE MANUAL

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@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 carefully 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

I. Specifications

A. Icemaker

1. DCM-500BAH

2. DCM-500BAH-OS

3. DCM-500BWH

4. DCM-500BWH-OS

II. General Information A. Construction B. Ice Making Unit C. Sequence of Operation

1. Fill Cycle

2. Ice Purge Cycle (60 seconds)

3. Freeze Cycle

4. Drain Cycle

5. Shutdown

D. Control Board

1. Control Board Layout

a) DCM-500BAH, DCM-500BWH

b) DCM-500BAH-OS, DCM-500BWH-OS

2. Features

3. Controls and Adjustments

4. Control Board Check Procedure

E. Float Switch III. Technical Information

A. Water Circuit and Refrigeration Circuit B. Wiring Diagrams

1. DCM-500BAH, DCM-500BWH

2. DCM-500BAH-OS, DCM-500BWH-OS

C. Sequence of Electrical Circuit – Ice Making

1. Fill Cycle

2. Ice Purge Cycle

3. Freeze Cycle

4. 12 Hour Drain Cycle / Drain Switch

5. Shutdown

6. Low Water Safety

7. High Pressure Switch

D. Sequence of Electrical Circuit – Dispensing

1. Continuous Dispense

2. Portion Dispense

E. Performance Data

1. DCM-500BAH(-OS)

2. DCM-500BWH(-OS)

IV. Service Diagnosis A. Diagnostic Procedure B. Ice Production Check C. Diagnostic Charts

1. No Ice Production

2. Low Ice Production

3. Other

4. Dispensing

5. Opti Serve (OS) Sensors

V. Removal and Replacement of Components A. Service for Refrigerant Lines

1. Refrigerant Recovery

2. Brazing

3. Evacuation and Recharge (R-404A)

B. Removal and Replacement of Compressor C. Removal and Replacement of Expansion Valve D. Removal and Replacement of Evaporator Assembly Components

1. Upper Bearing Wear Check

2. Removal and Replacement of Extruding Head

3. Removal and Replacement of Auger

4. Removal and Replacement of Evaporator

5. Removal and Replacement of Mechanical Seal and Lower Housing

6. Removal and Replacement of Gear Motor

E. Removal and Replacement of Self-Contained Air-Cooled Condenser F. Removal and Replacement of Water-Cooled Condenser G. Removal and Replacement of Water Regulating Valve - Water-Cooled Model Only ... 58 H. Adjustment of Water Regulating Valve - Water-Cooled Model Only I. Removal and Replacement of Fan Motor J. Removal and Replacement of Inlet or Dispensing Water Valve K. Removal and Replacement of Drain Valve L. Removal and Replacement of Dispensing System

1. Dispensing Auger and Agitator

2. Dispensing or Agitating Motor

VI. Cleaning and Maintenance A. Cleaning and Sanitizing Instructions

1. Water System

a) Cleaning Solution

b) Cleaning Procedure

c) Sanitizing Solution

d) Sanitizing Procedure - Following Cleaning Procedure

2. Dispensing Components

a) Cleaning Solution

b) Sanitizing Solution

c) Cleaning and Sanitizing Procedure

B. Maintenance C. Preparing the Icemaker for Long Storage

I. Specifications

A. Icemaker

1. DCM-500BAH

Note: We reserve the right to make changes in specifications and design without prior notice.

AC SUPPLY VOLTAGE 115/60/1

COMPRESSOR 120 V 7.9 RLA 51 LRA

GEAR MOTOR 120 V 2.4 FLA 1/4 HP

FAN MOTOR 120 V 1.0 FLA 50 W

AGITATING MOTOR 120 V 0.9 FLA 55 W

DISPENSING MOTOR 120 V 0.9 FLA 55 W

OTHERS 120 V 0.2 A

MAXIMUM FUSE SIZE 20 A

MAX. HACR BREAKER (USA ONLY) 20 A

MAX. CIRC. BREAKER (CANADA ONLY) 20 A

MINIMUM CIRCUIT AMPACITY 20 A

APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp. (°F) 50 70 90 lbs./day ( kg/day ) 70 *535 (243) 510 (231) 485 (220) Reference without * marks 80 461 (209) 438 (199) 416 (189)

90 396 (179) *385 (175) 358 (162) 100 340 (154) 323 (147) *304 (138)

SHAPE OF ICE Cubelet (Compressed Flake Ice) ICE QUALITY Apprx. 90% Ice (90/70° F, CONDUCTIVITY 200 µs/cm) APPROXIMATE STORAGE CAPACITY 40 lbs.

ELECTRIC & 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)

gal./24HR (gal./100 lbs.)

EXTERIOR DIMENSIONS (WxDxH) 26" x 22-1/2" x 40" ( 661 x 571 x 1016 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT NET 251 lbs. (114 kg), Shipping 276 lbs. (125 kg) CONNECTIONS - ELECTRIC Permanent Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT x2 ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger ( 1/4 HP Gear Motor ) ICE MAKING WATER CONTROL Float Switch

COOLING WATER CONTROL N/A

BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. ) COMPRESSOR Hermetic, Model RS43C2E-CAA-219 CONDENSER Air-cooled, Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R404A 1 lb 4.1 oz. (570g) DESIGN PRESSURE High 460 PSIG Low 290 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out Relay COMPRESSOR PROTECTION Auto-reset Overload Protector GEAR MOTOR PROTECTION Auto-reset Thermal Protector

Fuse REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch and Timer ACCESSORIES - SUPPLIED Spare Fuse

- REQUIRED Legs

OPERATING CONDITIONS VOLTAGE RANGE 104-127 V

AMBIENT TEMP. 45-100 F

WATER SUPPLY TEMP. 45-90 F

WATER SUPPLY PRESSURE 10-113 PSIG

ENG F-013.0.1196

2. DCM-500BAH-OS

Note: We reserve the right to make changes in specifications and design without prior notice.

AC SUPPLY VOLTAGE 115/60/1

COMPRESSOR 120 V 7.9 RLA 51 LRA

GEAR MOTOR 120 V 1.6 FLA 1/6 HP

FAN MOTOR 120 V 0.6 FLA 30 W

AGITATING MOTOR 120 V 0.9 FLA 55 W

DISPENSING MOTOR 120 V 0.9 FLA 55 W

OTHERS 120 V 0.2 A

MAXIMUM FUSE SIZE 20 A

MAX. HACR BREAKER (USA ONLY) 20 A

MAX. CIRC. BREAKER (CANADA ONLY) 20 A

MINIMUM CIRCUIT AMPACITY 20 A

APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp. (°F) 50 70 90 lbs./day ( kg/day ) 70 *525 (238) 510 (231) 485 (220) Reference without * marks 80 461 (209) 438 (199) 416 (189)

90 396 (179) *385 (175) 358 (162) 100 340 (154) 323 (147) *304 (138)

SHAPE OF ICE Cubelet (Compressed Flake Ice) ICE QUALITY Apprx. 90% Ice (90/70° F, CONDUCTIVITY 200 µs/cm) APPROXIMATE STORAGE CAPACITY 40 lbs.

ELECTRIC & 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)

gal./24HR (gal./100 lbs.)

EXTERIOR DIMENSIONS (WxDxH) 26" x 22-1/2" x 40" ( 661 x 571 x 1016 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT NET 251 lbs. (114 kg), Shipping 276 lbs. (125 kg) CONNECTIONS - ELECTRIC Permanent Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT x2 ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger ( 1/6 HP Gear Motor ) ICE MAKING WATER CONTROL Float Switch

COOLING WATER CONTROL N/A

DISPENSER CONTROL SYSTEM Photoelectric Sensor (Infrared) BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. ) COMPRESSOR Hermetic, Model RS43C2E-CAA-219 CONDENSER Air-cooled, Fin and tube type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R404A 1 lb 4.1 oz. (570g) DESIGN PRESSURE High 460 PSIG Low 290 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out Relay COMPRESSOR PROTECTION Auto-reset Overload Protector GEAR MOTOR PROTECTION Auto-reset Thermal Protector

Fuse REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch and Timer ACCESSORIES - SUPPLIED Spare Fuse

- REQUIRED Legs

OPERATING CONDITIONS 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.

3. DCM-500BWH

AC SUPPLY VOLTAGE 115/60/1

COMPRESSOR 120 V 7.9 RLA 51 LRA

GEAR MOTOR 120 V 2.4 FLA 1/4 HP

AGITATING MOTOR 120 V 0.9 FLA 55 W

DISPENSING MOTOR 120 V 0.9 FLA 55 W

OTHERS 120 V 0.2 A

MAXIMUM FUSE SIZE 20 A

MAX. HACR BREAKER (USA ONLY) 20 A

MAX. CIRC. BREAKER (CANADA ONLY) 20 A

MINIMUM CIRCUIT AMPACITY 20 A

APPROXIMATE ICE PRODUCTION Ambient PER 24 HR. Temp. (°F) lbs./day ( kg/day ) 70 * 567 (257) 549 (249) 539 (244) Reference without * marks 80 529 (240) 519 (2335) 509 (231)

90 500 (227) * 495 (224) 481 (218) 100 472 (214) 464 (210) * 428 (194)

SHAPE OF ICE Cubelet (Compressed Flake Ice) ICE QUALITY Approx. 90% Ice (90/70° F, Conductivity 200 µs/cm) APPROXIMATE STORAGE CAPACITY 40 lbs.

ELECTRIC & WATER CONSUMPTION 90/70°F

ELECTRIC W (kWH/100 lbs.) 967 (4.7)

POTABLE WATER 60 (12)

WATER - COOLED CONDENSER 352 (71.2)

gal./24HR (gal./100 lbs.)

EXTERIOR DIMENSIONS (WxDxH) 26" x 22-1/2" x 40" (661 x 571 x 1016 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 245 lbs. (111 kg), Shipping 269 lbs. (122 kg) CONNECTIONS - ELECTRIC Permanent Connection

- WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2"FPT

- DRAIN Outlet 3/4" FPT x2 Condenser Outlet 3/8" FPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger ( 1/4 HP Gear Motor ) ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL Automatic Water Regulator BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. ) COMPRESSOR Hermetic, Model RS43C2E-CAA-219 CONDENSER Water Cooled, Double Tube Type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R404A 14.1 oz. (400g) DESIGN PRESSURE High 460 PSIG Low 290 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out Relay COMPRESSOR PROTECTION Auto-reset Overload Protector GEAR MOTOR PROTECTION Auto-reset Thermal Protector

Fuse REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch and Timer ACCESSORIES - SUPPLIED Spare Fuse

- REQUIRED Legs

OPERATING CONDITIONS VOLTAGE RANGE 104-127 V

AMBIENT TEMP. 45-100°F

WATER SUPPLY TEMP. 45-90°F

WATER SUPPLY PRESSURE 10-113 PSIG

70/50°F 991 (4.1) 68 (12)

251 (44.3)

50 70 90

WATER TEMP. (°F)

4. DCM-500BWH-OS

Note: We reserve the right to make changes in specifications and design without prior notice.

AC SUPPLY VOLTAGE 115/60/1

COMPRESSOR 120 V 7.9 RLA 51 LRA

GEAR MOTOR 120 V 1.6 FLA 1/6 HP

AGITATING MOTOR 120 V 0.9 FLA 55 W

DISPENSING MOTOR 120 V 0.9 FLA 55 W

OTHERS 120 V 0.2 A

MAXIMUM FUSE SIZE 20 A

MAX. HACR BREAKER (USA ONLY) 20 A

MAX. CIRC. BREAKER (CANADA ONLY) 20 A

MINIMUM CIRCUIT AMPACITY 20 A

APPROXIMATE ICE PRODUCTION Ambient PER 24 HR. Temp. (°F) lbs./day ( kg/day ) 70 * 567 257 549 249 539 244 Reference without * marks 80 529 240 519 235 509 231

90 500 227 * 495 224 481 218 100 472 214 464 210 * 428 194

SHAPE OF ICE Cubelet (Compressed Flake Ice) ICE QUALITY Approx. 89% Ice (90/70° F, CONDUCTIVITY 200 µs/cm) APPROXIMATE STORAGE CAPACITY 40 lbs.

ELECTRIC & WATER CONSUMPTION 90/70°F

ELECTRIC W (kWH/100 lbs.) 930 (4.8)

POTABLE WATER 56 (12)

WATER - COOLED CONDENSER 465 (100)

gal./24HR (gal./100 lbs.)

EXTERIOR DIMENSIONS (WxDxH) 26" x 22-1/2" x 40" (661 x 571 x 1016 mm) EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear) WEIGHT Net 245 lbs. (111 kg), Shipping 269 lbs. (122 kg) CONNECTIONS - ELECTRIC Permanent Connection

- WATER SUPPLY Inlet 1/2" FPT Condenser Inlet 1/2"FPT

- DRAIN Outlet 3/4" FPT x2 Condenser Outlet 3/8" FPT ICE MAKING SYSTEM Auger type HARVESTING SYSTEM Direct Driven Auger ( 1/6 HP Gear Motor ) ICE MAKING WATER CONTROL Float Switch COOLING WATER CONTROL Automatic Water Regulator DISPENSE CONTROL SYSTEM Photoelectric Sensor (Infrared) BIN CONTROL SYSTEM Mechanical Bin Control ( Proximity Sw. ) COMPRESSOR Hermetic, Model RS43C2E-CAA-219 CONDENSER Water Cooled, Double Tube Type EVAPORATOR Copper Tube on Cylinder REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R404A 14.1 oz. (400g) DESIGN PRESSURE High 460 PSIG Low 290 PSIG P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out Relay COMPRESSOR PROTECTION Auto-reset Overload Protector GEAR MOTOR PROTECTION Auto-reset Thermal Protector

Fuse REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch LOW WATER PROTECTION Float Switch and Timer ACCESSORIES - SUPPLIED Spare Fuse

- REQUIRED Legs

OPERATING CONDITIONS VOLTAGE RANGE 104-127 V

AMBIENT TEMP. 45-100°F

WATER SUPPLY TEMP. 45-90°F

WATER SUPPLY PRESSURE 10-113 PSIG

50 70 90

WATER TEMP. (°F)

70/50°F 985 (4.0) 65 (12)

285 (52)

II. General Information

A. Construction

1. DCM-500BAH(-OS)

Storage BinInlet Water Valve

Reservoir

Control Box

Air-Cooled Condenser

Spout Cover

Evaporator Assembly

Compressor

Dispensing Motor

Agitating Motor

Agitator

Ice Dispensing Auger

Dispensing Water Valve

Gear Motor

Spout B

Float Switch

Dispense Mode Switch

Control Switch

Shutter Assembly

Power Switch

Drier

Spout A

Drain Water Valve

Expansion Valve

Door Switch

2. DCM-500BWH(-OS)

Storage BinInlet Water Valve

Reservoir

Control Box

Water-Cooled Condenser

Spout Cover

Evaporator Assembly

Compressor

Dispensing Motor

Agitating Motor

Agitator

Ice Dispensing Auger

Dispensing Water Valve

Gear Motor

Spout B

Float Switch

Dispense Mode Switch

Control Switch

Shutter Assembly

Power Switch

Drier

Spout A

Drain Water Valve

Door Switch

Expansion Valve

B. Ice Making Unit

1. DCM-500BAH(-OS), DCM-500BWH(-OS)

Cubelet Cutter

Allen Head Cap Screw

Gear Motor

Spline Coupling

O-Ring

Mechanical-Seal

Extruding Head and Upper Bearing

Hex Head Bolt with Washer

Auger

Evaporator

Housing and Lower Bearing

Cylinder

Insulation

Allen Head Cap Screw with Washer

Washer

M8×14

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, the door switch is engaged, and the control switch is in the "ICE" position, the "POWER" LED on the control board comes on.

1. 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".

2. Ice 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.

3. Freeze Cycle "COMP", "GM" LEDs are on. Comp 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.

4. 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.

5. 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

L eg en d

B

C b in c on tr ol

C o m p c om pr es so r D

C d ra in c yc le

D T d ra in ti m er D

V d ra in v al ve

F M

S s el f-co nt ai ne d fa n m ot or F

T fi ll tim er lo w w at er s af et y)

G

M g ea r m ot or

G M

P R g ea r m ot or p ro te ct r el ay

L

F /S lo w er fl oa t s w itc h

U F

/S u pp er fl oa t s w itc h W

C R w at er c on tr ol r el ay W

V in le t w at er v al ve

C o m p o n en ts

E n er g iz ed w h en t h e

C o n tr o l S w it ch is in t h e

"D R

A

IN

P o si ti o n T he

D R

A

IN

po si tio n on th e co nt ro l s w itc h is u se d w he n cl ea ni ng a nd s an iti zi ng th e un it.

T hi s al lo w s cl ea ne r an d sa ni tiz er to d ra in fr om th e re se rv oi r an d ev ap or at or a ss em bl y.

W he n sw itc hi ng to th e "D

R A

IN

po si tio n du rin g th e fr ee ze c yc le , t he d ra in v al ve d oe s no t e ne rg iz e un til th e se co nd s hu td ow n se qu en ce te rm in at es

2.

S hu td ow n

R es ta rt

N ot e:

T o by pa ss th e se co nd s hu td ow n se qu en ce , m ov e th e po w er s w itc h to th e

"O F

F po si tio n, p la ce th e co nt ro l s w itc h in th e "D

R A

IN

po si tio n, th en m ov e th e po w er s w itc h ba ck to th e "O

N po si tio n.

U F

/S o pe n

L F

/S o pe n

(W V o n)

W C

R o ff F

T s ta rt ed s ec

W V o n

C o m p c on tin ue s F

M S c on tin ue s G

M c on tin ue s

G M

P R c on tin ue s

D C

M -5

0B

A H

O

S

D C

M -5

0B

W H

O

S

S eq u en ce F lo w

C h ar t an d

C o m p o n en t

O p er at io n

1.

S ta rt u p

2.

Ic e P u rg e C yc le

W V o n

L F

/S c lo se d U

F /S c lo se d

(W V o ff)

W C

R o n W

V o ff G

M o n G

M P

R o n

C o m p o n

F M

S o n W

C R c on tin ue s G

M c on tin ue s

G M

P R c on tin ue s

P ow er s w itc h "O

N

C on tr ol s w itc h in

IC

E

1.

F ill C yc le

3.

F re ez e C yc le

R efi ll (9 se co n d s)

L F

/S c lo se d U

F /S c lo se d

(W V o ff)

W

C R o n

F T o ff

(9 se c.

W

V o ff C o m p c on tin ue s

F M

S c on tin ue s

G M c on tin ue s G

M P

R c on tin ue s

L o w W at er

S af et y

U F

/S o pe n

F T e xc ee de d C o m p c on tin ue s

F M

S c on tin ue s

G M c on tin ue s G

M P

R c on tin ue s

W V c on tin ue s

C o m p o ff

F M

S o ff W

V c on tin ue s

G M c on tin ue s G

M P

R c on tin ue s

G M o ff

G M

P R o ff

W V c on tin ue s un til

U

/S c lo se s s ec o n d s s ec o n d s

If re fil l > se c.

F T

, 1 s ec on d sh ut do w n se qu en ce b eg in s s ec o n d s se c.

S h u td o w n S eq u en ce

U

/S o pe n s ec o n d s

2.

S h u td o w n

R es ta rt s ec o n d s

1.

B in F u ll

C o m p o ff

F M

S o ff G

M c on tin ue s

G M

P R c on tin ue s

G M o ff

G M

P R o ff

D V o n

(D C o nl y)

3.

Ic em ak er is

O ff

B C o pe n or

D C s ta rt s

C o m p c on tin ue s F

M S c on tin ue s G

M c on tin ue s

G M

P R c on tin ue s

2.

Ic e P u rg e C yc le

4.

Ic e

L ev el L o w er ed

S ee

1.

F ill

C yc le ab ov e se co n d s

B C c lo se d o r

M in . D

T o ff (D

C o nl y)

D V o ff

(D C o nl y) h o u r

D T r es et

D C o nl y)

4.

H o u r D ra in

C yc le D

V o pe ns fo r m in ut es e ve ry ho ur s S ee

3.

H ou r

D ra in C yc le be lo w

3.

H o u r D ra in

C yc le S h u td o w n

R es ta rt 1.

D ra in C yc le in it ia s

2.

Ic e P u rg e C yc le

3.

D ra in C yc le

4.

h o u r D

C

R es ta rt

S ee

1.

F ill C yc le ab ov e

D V o n fo r m in u s

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 static 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.

Microprocessor (board revision level indicated by last 2 digits on label)

"POWER" LED

(lights when power is supplied to the board)

"FLUSH" LED

(X5 Relay) Drain Valve

"COMP" LED

(X2 Relay) Compressor, Fan Motor

10.5V Transformer

"GM" LED

(X1 Relay) Gear Motor

"DM" LED

(X4 Relay) Shutter Solenoid, Dispensing Auger Motor

24V In

24V Supply Out 115V In

Gear Motor Protect Relay Circuit

Portion Control Timer

"AM" LED

(X3 Relay) Agitating Motor

Drain Valve 24V Out

Dispensing Motor 115V Out

Agitating Motor 115V Out

115V In

Gear Motor 115V Out

115V In

Counter Reset Button (not used in this application)

Control Board Part Number 2A1592-01

1. Control Board Layout

a) DCM-500BAH, DCM-500BWH

Dispensing Components See "III.

B. Wiring Diagrams" for details.

Bin Control, Control Switch, Low Water Safety

High Pressure Switch

Flush Switch Must be left in the "P" position, otherwise the internal drain timer will not operate.

Dispensing Components See "III.B. Wiring Diagrams" for details.

Bin Control, Control Switch, Low Water Safety

Microprocessor (board revision level indicated by last 2 digits on label)

"POWER" LED

(lights when power is supplied to the board)

"FLUSH" LED

(X6 Relay) Drain Valve

"COMP" LED

(X2 Relay) Compressor, Fan Motor

10.5V Transformer

High Pressure Switch

"GM" LED

(X1 Relay) Gear Motor

"WTR" LED

(X5 Relay) Dispensing Water Valve

"ICE" LED

(X4 Relay) Shutter Solenoid, Dispensing Auger Motor

24V In

24V Supply Out 115V In

Gear Motor Protect Relay Circuit

Portion Control Timer

"AM" LED

(X3 Relay) Agitating Motor

Drain Valve 24V Out

Dispensing Motor 115V Out

Dispensing Water Valve 24V Out

24V In

Agitating Motor 115V Out

115V In

Gear Motor 115V Out

115V In

Counter Reset Button (not used in this application)

Control Board Part Number 2A2649-01

Flush Switch Must be left in the "P" position, otherwise the internal drain timer will not operate.

b) DCM-500BAH-OS, DCM-500BWH-OS

2. Features The control board provides the following safeguards:

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."

Icemaking

Cycle (Relay) LED Energized

Components Time LEDs are

On Frequency LEDs are

On Fill POWER only WV N/A As Needed Ice Purge (X1) GM GM 60 seconds N/A

Freeze (X1, X2) GM, COMP GM, Comp, FMS

N/A N/A

Drain Valve (X6) FLUSH DV 20 Minutes Every 12 Hours

Dispensing

Relay LED Energized

Component Time LEDs are

On Frequency LEDs are

On

Ice Dispense (X4)

Push Button

DM

IDM

60 seconds maximum

N/A Opti Serv

ICE

Agitating Motor (X3) AM AM .6 seconds Every 12 seconds of 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

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.).

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.

4. 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. 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] 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) Dispensing 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 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)

Upper Float (blue)

Magnet (towards top)

Magnet (towards top)

Lower Float (white)

Plastic Retainer Clip

Spring Retainer Clip

III. Technical Information

A. Water Circuit and Refrigeration Circuit

1. DCM-500BAH(-OS)

Inlet Water Valve

Dispensing Water Valve

Drain Valve

Float Switch

Water Level

To Drain

Evaporator

Spout

Expansion Valve

Gear Motor

Overflow

Reservoir

Water Supply

Drier

Air-Cooled Condenser

Fan

High Pressure Switch

Access Valve

Access Valve Compressor

Refrigeration Circuit

Water Circuit

Inlet Water Valve

Dispensing Water Valve

Drain Valve

Float Switch

Water Level

To Drain

Evaporator

Spout

Expansion Valve

Gear Motor

Overflow

Reservoir

Water Supply

Drier

Water-Cooled Condenser

High Pressure Switch

Access Valve

Access Valve Compressor

Water Supply In

Water Supply Out

Refrigeration Circuit

Water Circuit

Water Regulating Valve

(Control Board)

BK BLACK

BR BROWN

BU BLUE

DBU DARK BLUE

GY GRAY

LBU LIGHT BLUE

O ORANGE

P PINK

R RED

V VIOLET

W WHITE

Y YELLOW

W/BK WHITE/BLACK

W/BR WHITE/BROWN

W/BU WHITE/BLUE

W/O WHITE/ORANGE

W/R WHITE/RED

WIRE COLOR CODE

B. Wiring Diagrams

1. DCM-500BAH, DCM-500BWH

* High Pressure Switch

Air-Cooled Model Water-Cooled Model

Cut-out 412±21 PSIG 384±21 PSIG

Cut-in 327±21 PSIG 284±21 PSIG 0 0

2. DCM-500BAH-OS, DCM-500BWH-OS

BK BLACK

BR BROWN

BU BLUE

DBU DARK BLUE

GY GRAY

LBU LIGHT BLUE

O ORANGE

P PINK

R RED

V VIOLET

W WHITE

Y YELLOW

W/BK WHITE/BLACK

W/BR WHITE/BROWN

W/BU WHITE/BLUE

W/O WHITE/ORANGE

W/R WHITE/RED

WIRE COLOR CODE

(Control Board)

* High Pressure Switch

Air-Cooled Model Water-Cooled Model

Cut-out 412±21 PSIG 384±21 PSIG

Cut-in 327±21 PSIG 284±21 PSIG 0 0

C. Sequence of Electrical Circuit – Ice Making

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-OS

DCM-500BWH-OS

DCM-500BAH

DCM-500BWH

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board) (Control Board)

2. Ice Purge Cycle Upper float switch closes, water control relay energizes, inlet water valve closes, gear motor starts, gear motor protect relay energizes.

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board) (Control Board)

DCM-500BAH-OS

DCM-500BWH-OS

DCM-500BAH

DCM-500BWH

3. Freeze Cycle Compressor and fan motor start 60 seconds after gear motor starts.

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board)(Control Board)

DCM-500BAH-OS

DCM-500BWH-OS

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.

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board) (Control Board)

DCM-500BAH-OS

DCM-500BWH-OS

DCM-500BAH

DCM-500BWH

12 Hour Drain Cycle

Manual Drain Cycle

12 Hour Drain Cycle

Manual Drain Cycle

5. Shutdown The bin control switch is activated 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.

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board) (Control Board)

DCM-500BAH-OS

DCM-500BWH-OS

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.

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board) (Control Board)

DCM-500BAH-OS

DCM-500BWH-OS

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.

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board) (Control Board)

DCM-500BAH-OS

DCM-500BWH-OS

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 is 60 seconds. After 60 seconds, the dispense switch must be disengaged and engaged again.

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board) (Control Board)

DCM-500BAH-OS

DCM-500BWH-OS

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 "II.

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.

Amount of ice dispensed per second.

DCM-500BAH(-OS), DCM-500BWH(-OS) . . . . . . . . . . . . Approximately 1.2 oz.

BK BLACK O ORANGE W/BK WHITE/BLACK

BR BROWN P PINK W/BR WHITE/BROWN

BU BLUE R RED W/BU WHITE/BLUE

DBU DARK BLUE V VIOLET W/O WHITE/ORANGE

GY GRAY W WHITE W/R WHITE/RED

LBU LIGHT BLUE Y YELLOW

WIRE COLOR CODE

(Control Board) (Control Board)

DCM-500BAH-OS

DCM-500BWH-OS

E. Performance Data

1. DCM-500BAH(-OS)

Note:

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.

APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F)

PER 24 HR. 70 *535 (243) 510 (231) 485 (220)

80 461 (209) 438 (199) 416 (189) 90 396 (179) *385 (175) 358 (162) lbs./day ( kg/day) 100 340 (154) 323 (147) *304 (138)

APPROXIMATE ELECTRIC 70 *985 -- 995 -- 1005 --

CONSUMPTION 80 1015 -- 1025 -- 1035 --

90 1045 -- *1055 -- 1056 --watts 100 1058 -- 1059 -- *1060 --

APPROXIMATE WATER 70 *64 (243) 61 (231) 58 (220)

CONSUMPTION PER 24 HR. 80 55 (209) 53 (199) 50 (189)

90 48 (179) *46 (175) 43 (162) gal. / day (l/day) 100 41 (154) 39 (147) *37 (138)

EVAPORATOR OUTLET TEMP. 70 *23 (-5) 23 (-5) 23 (-5)

°F (°C) 80 23 (-5) 26 (-4) 26 (-4)

90 26 (-4) *26 (-4) 28 (-3) 100 28 (-3) 28 (-3) *28 (-3)

HEAD PRESSURE 70 *230 (16.2) 230 (16.2) 230 (16.2)

80 264 (18.5) 264 (18.5) 264 (18.5) 90 297 (20.9) *297 (20.9) 297 (20.9)

PSIG (kg/cm2G) 100 335 (23.5) 335 (23.5) *335 (23.5)

SUCTION PRESSURE 70 *33 (2.3) 33 (2.3) 33 (2.3)

PSIG (kg/cm2G) 80 35 (2.5) 35 (2.5) 35 (2.5)

90 37 (2.6) *37 (2.6) 37 (2.6) 100 43 (3.0) 43 (3.0) *43 (3.0)

TOTAL HEAT OF REJECTION 6300 BTU/h (AT 90°F /WT 70°F)

50 70 90

Note:

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.

APPROXIMATE Ambient Water Temp. (°F) ICE PRODUCTION Temp. (°F)

PER 24 HR. 70 * 567 257 549 249 539 244

80 529 240 519 235 509 231 90 500 227 * 495 224 481 218 lbs./day ( l/day) 100 472 214 464 210 * 428 194

APPROXIMATE ELECTRIC 70 * 976 -- 967 -- 991 --

CONSUMPTION 80 976 -- 967 -- 991 --

90 976 -- * 967 -- 991 --watts 100 976 -- 967 -- * 991 --

APPROXIMATE WATER 70 * 111 0.51 130 0.59 194 0.88

CONSUMPTION PER 24 HR. 80 111 0.50 130 0.59 198 0.90

(TOTAL) 90 110 0.50 * 130 0.59 203 0.92

gal. / day (kl/day) 100 110 0.50 132 0.60 * 214 0.97

EVAPORATOR OUTLET TEMP. 70 * 19 -7 19 -7 19 -7

°F (°C) 80 19 -7 19 -7 19 -7

90 19 -7 * 19 -7 19 -7 100 19 -7 19 -7 * 19 -7

HEAD PRESSURE 70 * 266 18.7 267 18.8 270 19.0

80 266 18.7 267 18.8 270 19.0 90 266 18.7 * 267 18.8 270 19.0

PSIG (kg/cm2G) 100 266 18.7 267 18.8 * 270 19.0

SUCTION PRESSURE 70 * 44 3.1 44 3.1 47 3.3

PSIG (kg/cm2G) 80 44 3.1 44 3.1 47 3.3

90 44 3.1 * 44 3.1 47 3.3 100 44 3.1 44 3.1 * 47 3.3

HEAT OF REJECTION FROM CONDENSER

PRESSURE DROP OF COOLING WATER LINE

HEAT OF REJECTION FROM COMPRESSOR

5438 BTU/h (AT 90°F /WT 70°F) Less than 7 PSIG

1104 BTU/h (AT 90°F /WT 70°F)

50 70 90

WATER FLOW FOR CONDENSER 21 gal/h (AT 90°F /WT 70°F)

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. Remove 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 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.

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. 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) Shutdown – 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 "III.E. Performance Data."

C. Diagnostic Charts

1. No Ice Production Problem Possible Cause Remedy

[1] The icemaker will not start. (Fill Cycle)

a) Power Supply 1. Off, blown fuse, or tripped breaker.

1. Turn on, replace, or reset.

2. Loose connection. 2. Tighten.

3. Bad contacts. 3. Check for continuity and replace.

4. Not within specifications.

4. Refer to nameplate and correct.

b) Water Supply 1. Water supply off or pressure too low.

1. Check and get recommended pressure.

c) Power Switch (Control Box)

1. "OFF" position. 1. Move to "ON" position.

2. Bad contacts. 2. Check for continuity and replace.

d) Door Switch 1. Door switch not engaged.

1. Engage door switch.

2. Bad contacts. 2. Check for continuity and replace.

e) Power Protect Relay 1. Voltage not within specifications.

1. Refer to nameplate and correct.

2. Bad contacts. 2. Check for continuity and replace.

f) Transformer 1. Coil winding open. 1. Replace.

g) Fuses (2) 1. Blown. 1. Check for short circuit and replace.

h) Control Switch 1. "OFF" or "DRAIN" position.

1. Move to "ICE" position.

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 clogged.

1. Clean.

2. Coil winding open. 2. Replace.

3. Wiring to inlet water valve.

3. Check for loose or open connection. Repair or replace.

k) Float Switch 1. Bad contacts. 1. Check for continuity and replace.

2. Float does not move freely.

2. Clean or replace.

l) Bin Control 1. Open. 1. Bin full, check for continuity on proximity switch.

2. Actuator sticking. 2. Adjust or replace.

3. Proximity switch open. 3. Replace.

Problem Possible Cause Remedy

[1] The icemaker will not start. (Fill Cycle) (continued) m)High Pressure Switch 1. Bad contacts. 1. Check for continuity and replace.

2. Dirty air filter or condenser.

2. Clean.

3. Ambient or condenser water temperature too warm.

3. Reduce temperature.

4. Refrigerant overcharged.

4. Recover, evacuate, and recharge.

5. Fan not operating (except water-cooled model).

5. See "3.[2]a) Fan Motor."

6. Refrigerant line or components restricted.

6. Remove the restriction or component and replace the drier.

7. Condenser water pressure too low or off (water-cooled model only).

7. Check and get recommended pressure.

8. Water regulating valve set too high (water-cooled model only).

8. Adjust it lower.

n) Plug and Receptacle (Control Box)

1. Disconnected. 1. Connect.

2. Loose terminal. 2. Repair terminal connection.

o) Control Board 1. Defective. 1. See "II.D.4. Control Board Check Procedure."

[2] Fill cycle will not terminate.

a) Water Supply 1. Water supply off or pressure too low.

1. Check and get recommended pressure.

b) Float Switch 1. Connector disconnected.

1. Reconnect.

2. Float does not move freely.

2. Clean or replace.

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 and water leaking.

1. Clean or replace.

e) Hoses 1. Disconnected or damaged.

1. Reconnect or replace.

f) Control Board 1. Defective. 1. See "II.D.4. Control Board Check Procedure."

[3] Ice purge cycle will not start.

a) Water Control Relay 1. Low water safety circuit open (bad contacts ).

1. Replace.

b) Control Switch 1. Bad contacts. 1. Check for continuity and replace.

c) Bin Control 1. Open. 1. Bin full, check for continuity on proximity switch.

d) Control Board 1. Fails to operate gear motor relay.

1. See "II.D.4. Control Board Check Procedure."

e) Gear Motor Fuse 1. Blown. 1. Check gear motor amperage, bearing wear (see "V.F.1. Upper Bearing Wear Check"), and supply voltage.

f) Gear Motor Thermal Protector

1. Open. 1. Check gear motor bearings, supply voltage.

g) Gear Motor 1. Open windings. 1. Replace.

2. Auger coupling broke. 2. Replace.

3. Locked bearings. 3. Replace.

[4] Freeze cycle will not start (compressor).

a) Gear Motor Protect Relay

1. Open coil. 1. Replace.

2. Open contacts. 2. Replace.

b) Control Board 1. Defective. 1. See "II.D.4. Control Board Check Procedure."

c) Starter (Start Relay) 1. Bad contacts. 1. Check for continuity and replace.

2. Coil winding open. 2. Replace.

3. Loose connections. 3. Tighten.

d) Start Capacitor or Run Capacitor

1. Defective. 1. Replace.

e) Compressor 1. Power supply not within specifications.

1. Refer to nameplate and correct.

2. Wiring to compressor. 2. Check for loose or open connection, repair or replace.

3. Defective. 3. Replace.

4. Compressor locked and internal motor protector tripped.

4. Replace.

[5] All components run, but no ice is produced.

a) Refrigerant 1. Low charge. 1. See "V.B. Service for Refrigerant Lines."

2. Refrigerant line or component restricted.

2. Remove the restriction or component and replace the drier.

3. Air or moisture trapped.

3. Recover refrigerant, replace drier, evacuate, and recharge.

b) Expansion Valve 1. Bulb loose. 1. Secure bulb.

2. Operating erratically. 2. Check and replace.

c) Compressor 1. Defective. 1. Replace.

[5] All components run, but no ice is produced. (continued)

d) Evaporator 1. Defective. 1. Replace.

e) Water Supply Line (water-cooled model only)

1. Condenser water pressure too low or off and high pressure control opens and closes frequently.

1. Check and get recommended pressure.

f) Water Regulating Valve (water-cooled model only)

1. Water regulating valve set too high or clogged (water-cooled model only).

1. Clean, adjust, or replace.

2. Low Ice Production Problem Possible Cause Remedy

[1] Low ice production. a)Evaporator 1. Dirty or defective. 1. Clean or replace.

b)Bin Control 1. Erratic, sticking, defective.

1. Clean or replace.

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 component restricted.

1. Repair/replace the clogged line/component and replace the drier.

g)High-Side Pressure Too High

1. Dirty…