Hobart Food Machines HQC45 Service Manual

SERVICE MA NUAL

HQC45 & 90 SERIES

QUICK CHILLERS

MODEL ML#

HQC45 ML # 124059 HQC45 ML # 124066 HQCF45 ML # 124060 HQCF45 ML # 124067 HQC90 ML # 124063 HQC90 ML # 124068

- NOTICE This Manual is prepared for the use of trained Hobart Service Technicians and should not be used by those not properly qualif ied. If you have attended a Hobart Service School for this product, you may be qualified to perform all the procedures described in this manual.

Thi s manual is not inten ded to be al l encompassing. If yo u have not attended a Hobart Service School for this product, you should read, in its entirety, the repair procedure you wish to perform to determine if you have the n ecessary t ools, instruments and skills required to perform the procedure. Procedures f or which you do not have the necessary t ools, instruments and skills should be performed by a trained Hobart Service Technician.

Reproduction or other use of this Manual, without the express written consent of Hobart Corporation, is prohibited.

A product of HOBART CORP ORATION TROY, O H 45374- 0001

Form 24693 ( M ar c h 2001)

Supercedes F-24664 and F-24603

HQC45/HQCF45/HQC90 QUICK CHI LLE R

TABLE OF CONTENTS

GENERAL............................................................................. 3

Introduction ........................................................................ 3

Operation.......................................................................... 3

Cleaning .......................................................................... 3

Tools ............................................................................. 3

Specifications ...................................................................... 4

REMOVAL AND REPLACEMENT OF PARTS ................................................. 5

Covers and Panels ................................................................... 5

Controller Assembly.................................................................. 6

Temperature Sensors ................................................................ 7

Air Sensor ..................................................................... 8

Expansion Valve .................................................................... 8

Door Gasket........................................................................ 9

Heaters ........................................................................... 9

Defrost Heater .................................................................. 9

Door Frame Heater ............................................................. 10

Food Temperature Probe Receptac le ................................................... 10

Condensing Unit Components ......................................................... 11

Compressor ................................................................... 11

Condenser Fan Assembly ......................................................... 11

Condenser Coil ................................................................. 11

Pressure Control................................................................ 12

Filter/Drier .................................................................... 12

Evapor ator Coil .................................................................... 12

Evapor ator Fan .................................................................... 13

Hot Gas Condensate Pan ............................................................. 13

SERVICE PROCEDURES AND ADJUSTMENTS .............................................. 14

Refrigeration Control Adjustments ...................................................... 14

TEV Superheat A djustment ........................................................... 15

Checking for Leaks ................................................................. 15

Evacuating System ................................................................. 16

Charging System ................................................................... 16

System Cl ean Up ................................................................... 17

Serv ice Mode ML-124059, M L- 124060, ML-124063 ......................................... 17

Serv ice Mode ML-124066, M L- 124067, ML-124068 ......................................... 19

Factory Settings Mode ML-124066, M L- 124067, ML-124068 .................................. 22

Software Ver si on M L- 124059, ML-124060, ML-124063 ...................................... 24

Software Ver si on M L- 124066,ML-124067,ML-124068 ....................................... 24

Controll er Serv ice Procedures ML-124059,M L-124060, ML-124063 ............................. 25

Controll er Serv ice Procedures ML-124066, M L-124067, ML-124068 ............................ 27

ELECTRICAL OPERATION .............................................................. 29

Component Locat ion ................................................................ 29

Component Func tion ................................................................ 31

Sequence of O per ation ML-124059, M L- 124060, ML-124063 .................................. 32

Sequence of O per ation ML-124066, M L- 124067, ML-124068 .................................. 33

Schematics ....................................................................... 35

TROUBLESHOOTING .................................................................. 41

System Troubleshooting ............................................................. 41

Product Tr oubleshooting ............................................................. 44

CONDENSED SPARE PARTS LIST ........................................................ 44

Form 24693 ( M ar c h 2001) Page 2 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - GENERAL

GENERAL

INTRODUCTION

Chillers are food processing refrigerators designed for rapidly chilling product from 150° F to approximately 37° F in approximately 90 mi nutes for reheating at a later time. Quick Freezers are designed for r apidly freezing product as well as rapidly chilling product.

These units aid in preserving food quality, texture and nutritional value.

All of the information, illustrations and specific ations contained i n this manual ar e based on the latest product information availabl e at the time of printing.

OPERATION

Refer to the Instruction manual for specific operating i nst r uc tions.

CLEANING

TOOLS

Standard

• Standard set of hand tools.

• Temperat ure tester or thermometer.

• VOM with AC current tester.

• Electricall y c onduc tive field service grounding kit (p/ n TL84919).

Special

• Refri geration Recl aiming E quipment

• Acetylene torch

• Nitrogen bottle with gauges

• Refri geration gauge m anifol d

• Dial-a-charge

• Valve core rem oval tool

• Vacuum pump

Detailed c leaning instr uc tions are incl uded wi th each unit, however, special care must condenser coil. The condenser coil must be cleaned weekly grease for proper system operation. This can be done with a v acuum cleaner usi ng a br ush attachm ent, or a stiff brush or whisk broom. Care must fins.

. This surface must be kept free of dirt and

be taken not to damage the condenser coil

be given to the

Form 24693 ( M ar c h 2001)Page 3 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - GENERAL

SPECIFICATIONS

DATA

HQC45 HQCF45 HQC90

H.P. 1 BTU/HR 9900 @ 25(F Evaporator

Temp Refri ger ant Type R-404A R-404A R-404A Refri ger ant Charge (oz) 160 160 160 Cond Unit Amp Draw (RLA) 1 phase = 8.1A 1 phase = 9.0A 1 phase = 12A

Evapor ator Fans Amp Draw 1.1A 1.1A 1.1A Voltage 208,240/60/1 208,240/60/1 208,240/60/1 Amps 10.8A 10.8A 13.8A Optional Voltage N/A N/A 208-240/60/3 Optional Amps N/A N/A 10.4A

8050 @ 0(F Evaporator Temp

11/

13/

14700 @ 25(F Evapor ator Temp

3 phase = 8.6A

Operatin g Data

Refri ger ant R-404A Ambient Temperature 70(F 100(F Suction Pressure PSIG

(Chill Mode)

Start of cycle 75 75 End of cycle 28 32

Suction Pressure PSIG

(Freezer Mode)

Start of cycle 55 55 End of cycle 5 6

Discharge Pressure PSIG

Start of cycle 340 420 End of cycle 225 300

DIMENSIONS

(inches)

HQC45

HQC90

HQCF45

Width 32 32 Depth 37 44½ Height 70 77½ Width (cavity ) 28 28 Depth (cavity) 19 Height (cavit y) 27½ 27½ Height to bottom of cavity 27½ 35½

Form 24693 ( M ar c h 2001) Page 4 of 44

26¾

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

REMOVAL AND REPLACEMENT OF PARTS

COVERS AND PANELS

Condensing Unit Covers (Front and Rear)

1. Pull t he c over toward you to pull the V E LCRO apart at each cor ner of the cover.

Evaporator Cover WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Remove the tracks (HQC90) or the shelves and back shelf clips f r om the cabinet.

2. Remove the screws that secure the evaporator cover and remove it from the c abinet.

NOTE:

DISCONNECT THE ELECTRICAL

The ev apor ator fan panel can be opened.

2. Reverse proc edur e to install .

Top and Rear Covers WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Remove the screws from the edges of the top cover and remove it from the machine.

2. Remove the screws from the edges of the rear cover and remove it from the machine.

DISCONNECT THE ELECTRICAL

3. Reverse proc edur e to install .

Form 24693 ( M ar c h 2001)Page 5 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

CONTROLLER ASSEMBLY

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

CAUTION: Electro-static discharge will damage the control board. Use a anti-static grounding kit when servicing the computer con t rol box.

Procedure

1. Remove the top cover as outlined under "COVERS AND PANELS".

2. Disconnect the plugs from the control box or control panel.

3. Remove the connectors from t he c ontrol box or controller, if necessary.

Removable Components Only fo r ML-124059,ML- 124060,ML-124063

DISCONNECT THE ELECTRICAL

4. Open the door to t he control box or control panel and remove the screws that secure computer control box or controller to f r ont of cabinet.

5. Remove the control box or cont r oller from the cabinet.

6. Reverse the procedure to install.

Form 24693 ( M ar c h 2001) Page 6 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

Removable Components Only fo r HQC45 ML-124066, HQCF45 ML-124067,HQ C90 M L-124068

Form 24693 ( M ar c h 2001)Page 7 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

TEMPERATURE SENSORS

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Air Sensor

1. Remove the evaporator cover as outlined under "COVERS A ND P A NE LS " .

2. Remove the air t emperature sensor f r om its locati on in the return air duct.

3. Disconnect the lead wires.

DISCONNECT THE ELECTRICAL

EXPANSION VALVE

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING:

USE OF REF RIGERANTS. B E CE RTAIN THE WORK AREA IS WELL VENTILATED. SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRI GERANTS MAY CAUS E B URNS TO THE SKIN.

1. Pump-down refrigeration system.

WARNING:

LINES WILL CONTAIN PRESSURE.

2. Access the expansion valve through t he front of the cabinet. The expansion valve is located behind the evaporator fans.

3. Detach expansion val ve bulb from suct ion line.

4. Remove expansion valve from the l iquid line at inlet and outlet of valve.

5. Install new expansion valve into inl et line and fasten bulb to suction line. Initial setting: 3½ turns counterclockwise.

DISCONNECT THE ELECTRICAL

THIS PROCE DURE RE QUIRES THE

AFTER PUMP - DOWN, REFRIGERANT

4. Reverse proc edur e to install .

Coil Sensor

1. Remove the evaporator cover as outlined under "COVERS A ND P A NE LS " .

2. Remove the air t emperature sensor f r om its locati on on the evapor ator coil.

3. Disconnect the lead wires.

4. Reverse proc edur e to install .

NOTE:

attached paral lel to suction line and makes good contact.

NOTE:

the diaphragm of the valve.

NOTE:

changed when this part is replaced.

Make sure expansion valve bulb is

Expansion valve bulb must be lower than It is recommended that the filter/dr ier be

Form 24693 ( M ar c h 2001) Page 8 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

6. Recharge unit and c hec k for leaks.

7. Put unit bac k into operation and check the superheat as outlined under " TEV SUPERHEAT ADJUSTMENT" in "SERVICE PROCEDURES AND ADJUSTMENTS".

DOOR GASKET

1. Select Stand-by Mode.

2. Open door to m aximum position.

3. Remove door gasket by pulling arrow shaped retaini ng tab from the retai ning channel around the outer edge of the door.

CAUTION: When handling a new door gasket, DO NOT material will stretch at room temperature and will NOT

4. Position the corners of the gasket at the top

pull on the gasket mat erial. T he gasket

return to its original length.

corners of t he door and push straight in on the gasket until the arrow tab is lock ed in the retaini ng channel.

6. Install side by starting at the top and working down, making sure t he end of the gasket meets with the edge of the door.

7. Check door for proper operation.

HEATERS

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Defrost Heater

1. Remove the evaporator cover as outlined under "COVERS A ND P A NE LS " .

2. Disconnect wire leads to defrost heater .

3. Unscrew floor brac k et in fr ont of the evaporator coil.

4. Remove the copper wires holding defrost heater(s) in place.

DISCONNECT THE ELECTRICAL

5. Start the c enter of t he top and work the gasket in place from the center to each cor ner .

5. Remove the defr ost heater from the coil being careful to prevent damage t o c oil f ins.

6. Reverse proc edur e to install .

Form 24693 ( M ar c h 2001)Page 9 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

Door Frame Heater

1. Open door past 90°.

2. Remove door frame heater covers fr om the door frame by gently pr y ing out on the insi de edge of the cover.

NOTE:

to install.

3. Pull t he door frame heater wire loose from the

Do not bend the covers. They will be difficult

door frame channel.

FOOD TEMPERATURE PROBE

RECEPTACLE

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Turn chiller OFF or select Stand-by Mode were applicable.

2. Remove the probe recept ac le cov er .

NOTE:

are properly in-place between probe receptacle housing and cov er.

DISCONNECT THE ELECTRICAL

When installing the cover, insure grommets

4. Disconnect the suppl y lead wires from each end of the heat er , and the (green) ground lead wire from one end.

5. Connect lead wires to r eplacement heater.

6. Insert the heater into the door frame channel.

NOTE:

frame.

7. Install heater covers. The horizontal one first.

NOTE:

corners of t he door frame.

8. Check for proper operation of the door and

Form 24693 ( M ar c h 2001) Page 10 of 44

Do not kink heat er wire at the corners of the

A. Hook the inside edge of the heater c over

over the lip of the door frame.

Check positi on of heater cover in the top

B. Use your fingers to push the outside edge

over the outside lip of the heat er c hannel in the door frame.

C. Repeat for each side.

door frame heater.

3. Unplug the probe.

4. Reverse the procedure to install.

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

CONDENSING UNIT

COMPONENTS

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

Compressor WARNING:

USE OF REF RIGERANTS. B E CE RTAIN THE WORK AREA IS WELL VENTILATED. SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRI GERANTS MAY CAUS E B URNS TO THE SKIN.

1. Remove the condensing uni t cover s as outl ined under “COVERS AND PANELS”.

2. Evac uate refrigeration system.

NOTE:

mandatory.

3. Disconnect lead wi r es and conduit at the compressor junction box.

4. Disconnect suction and discharge li nes from the compressor.

DISCONNECT THE ELECTRICAL

THIS PROCE DURE RE QUIRES THE

The use of reclaiming equipment is

3. Remove the mot or and fan assembly from the mounti ng bracket.

4. To replace the fan blade only, f ollow steps 4A & 4B. To replace the motor, perf or m step 4A and proceed to step 5.

A. Loosen the set screw that secures the fan

blade to the motor shaft and remove the fan blade from the motor.

B. Install the new fan blade with the set

screws between the motor and the bl ades and rever se t he pr oc edur e to install .

5. Disconnect the lead wires from the motor .

6. Reverse the procedure to install.

Condenser Coil WARNING:

USE OF REF RIGERANTS. B E CE RTAIN THE WORK AREA IS WELL VENTILATED. SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRI GERANTS MAY CAUS E B URNS TO THE SKIN.

1. Evac uate refrigeration.

NOTE:

mandatory.

2. Remove fan guard and fan shroud from condensing coil.

THIS PROCE DURE RE QUIRES THE

The use of reclaiming equipment is

5. Remove the compr essor.

6. Install new compressor and connect wire leads and conduit at c ompressor junction box.

7. Install a new filt er /drier.

8. Evac uate system.

9. Charge system and put unit into operation.

Condenser Fan Assembly

1. Remove the fan guar d from the top of t he condenser assembly.

3. Disconnect i nlet and outlet lines at the sol der ed connections nearest t he c ondenser coil.

4. Remove coil from mounting plate.

5. Reverse proc edur e to install c oil, then pr oc eed to next step.

NOTE:

changed when this part is replaced.

6. Evac uate system.

NOTE:

mandatory.

7. Charge system and put unit into operation.

It is recommended that the filter/dr ier be

The use of reclaiming equipment is

2. Remove the screws from the mounti ng c lamps on the front and rear of the motor.

Form 24693 ( M ar c h 2001)Page 11 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

Pressure Control WARNING:

USE OF REF RIGERANTS. B E CE RTAIN THE WORK AREA IS WELL VENTILATED. SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRI GERANTS MAY CAUS E B URNS TO THE SKIN.

1. Pump-down refrigeration system.

WARNING:

LINES WILL CONTAIN PRESSURE.

2. Front seat the suct ion service valve.

3. Disconnect wire leads to pressure switch.

4. Disconnect capillary tube from c ompressor fitting.

5. Remove pressure control from mounting bracket.

6. Replace pressure switch and connect c apillary tube to com pressor fitt ing.

7. Put unit bac k into operation.

Filter/Drier WARNING:

USE OF REF RIGERANTS. B E CE RTAIN THE WORK AREA IS WELL VENTILATED. SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRI GERANTS MAY CAUS E B URNS TO THE SKIN.

Pump-down refrigeration system.

WARNING:

LINES WILL CONTAIN PRESSURE.

1. Remove fi lter/drier from liquid line.

THIS PROCE DURE RE QUIRES THE

AFTER PUMP - DOWN, REFRIGERANT

THIS PROCE DURE RE QUIRES THE

AFTER PUMP - DOWN, REFRIGERANT

EVAPORATOR COIL

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

WARNING:

USE OF REF RIGERANTS. B E CE RTAIN THE WORK AREA IS WELL VENTILATED. SAFETY GOGGLES AND GLOVES SHALL BE WORN SINCE REFRI GERANTS MAY CAUS E B URNS TO THE SKIN.

1. Remove the evaporator cover and top cover as outlined under "COVERS AND PANE LS " .

2. Pump-down system.

WARNING:

LINES WILL CONTAIN PRESSURE.

3. Remove the defr ost heaters as outlined under “DEFROST HEATERS”.

4. Disconnect the suct ion line at the soldered joint closest to the coil.

NOTE:

mandatory.

5. Disconnect the liquid line at the expansion valve.

6. Remove the screws from the coil mounting bracket.

7. Pull t he coil out of the cabi net through the front.

8. Reverse proc edur e to install c oil, then pr oc eed to next step.

DISCONNECT THE ELECTRICAL

THIS PROCE DURE RE QUIRES THE

AFTER PUMP - DOWN, REFRIGERANT

The use of reclaiming equipment is

NOTE:

changed when this part is replaced.

9. Evac uate system.

10. Charge system and put unit into operation.

2. Install a new filt er /drier.

3. Evac uate system.

NOTE:

mandatory.

4. Charge system and put unit into operation.

Form 24693 ( M ar c h 2001) Page 12 of 44

The use of reclaiming equipment is

It is recommended that the filter/dr ier be

HQC45/HQCF45/HQC90 QUICK CHI LLE R - RE M OVAL AND REPLACEME NT OF PARTS

EVAPORATOR FAN

WARNING:

POWER TO T HE MACHINE AT THE MAIN CIRCUIT BO X. P LA CE A TAG ON THE CI RCUIT BOX INDICATING THE CIRCUIT IS BEING SERVICED.

1. Remove the top and rear c overs as outlined under “COVERS AND PANELS”.

2. Remove the tracks or shel ves fr om the cabinet and remove the shelf clips from the left r ear shelf support.

3. Remove the evaporator cover and open the evaporator fan panel as out lined under"COVERS A ND P A NE LS " .

DISCONNECT THE ELECTRICAL

5. Remove the bolts that secure the evaporator fan from the housing panel.

6. Remove the fan from the cabinet.

CAUTION: Do not attempt t o disassembly motor or remove fan blades from mo t or, blades are not available as a service part.

7. Reverse the procedure to install.

4. Disconnect the lead wires at the junction box on the top of the unit and pull them into the cavity with the fan.

HOT GAS CONDENSATE PAN

1. Remove the condensing uni t cover as outlined under “COVERS AND PANELS”.

2. Remove the bolts that secure the hot gas coil from the pan.

CAUTION: Do not damage the coil during removal.

3. Lift the hot gas coil out of t he pan.

4. Lift the hot gas pan to pull the Velcr o apar t from the pan to the uni t.

5. Reverse proc edur e to install .

Form 24693 ( M ar c h 2001)Page 13 of 44

HQC45/HQCF45/HQC90 QUICK CHI LLE R - S E RV ICE PROCEDURES AND ADJ U S TMENTS

SERVICE PROCEDURES AND A DJUSTMENTS

WARNING:

MEASUREMENTS WHILE THE POWER IS APPLIED TO THE MACHINE. EXERCISE EXTREME CAUTION AT ALL TIMES. IF TEST POINTS ARE NOT EASI LY ACCESSIBLE, DISCONNECT POWER, ATTACH TEST EQUIPMENT AND REAPPLY POWER TO TEST .

Expansion Valve

1. Access the expansion valve behind t he evaporator fans.

2. Remove seal cap from the side of the expansion valve.

3. Turn adjusting stem cloc k wise and seat valve.

4. Turn adjusting stem 2-1/2 t ur ns counterclockwise. This is the initial setting.

5. Reassemble unit and c hec k for proper operation.

Dual Pressure Co ntrol

CERTAIN PROCEDURES IN THIS SECTION REQUIRE ELECTRICAL TEST OR

REFRIGERATION CONTROL

ADJUSTMENTS

CPR Valve Only fo r HQC45 ML124059, HQCF 45 ML124060,

HQC90 ML124063

1. Remove the rear condensing unit cover.

2. Remove the insulation fr om the valve.

1. Turn low pressure adjustm ent "cut-i n" screw to

the initial setting of

2. Turn diff adj ust ment screw to the initial setting

psi.

3. Turn high pressure adjustment "cut- out" screw to the initial setting of

psi.

440

psi.

3. Connect the pressure gauge to the suct ion port of the compressor.

4. Operate the cabinet with the door open or with hot product.

5. Adjust the CPR valve so the maxim um

pressure is

psig.

4. Check for proper operation.

Form 24693 ( M ar c h 2001) Page 14 of 44

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