Hoshizaki CR60A, CR49A, R2AHS, CR36A, R2AFG User Manual

Service Manual

Steelheart Series
Refrigerated Kitchen Equipment

Models
Upright Series

hoshizakiamerica.com

Number: 73237
Issued: 2-25-2019
Revised: 5-8-2019

WARNING

Only qualied service technicians should install and service the appliance. To
obtain the name and phone number of your local Hoshizaki Certied Service
Representative, visit www.hoshizaki.com. No service should be undertaken until
the technician has thoroughly read this Service Manual. Failure to service and
maintain the appliance in accordance with this manual will adversely affect safety,
performance, component life, and warranty coverage. Proper installation is the
responsibility of the installer. Product failure or property damage due to improper
installation is not covered under warranty.

Hoshizaki provides this manual primarily to assist qualied service technicians in the
service and maintenance of the appliance.

Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call, send an e-mail message, or write to the Hoshizaki Technical
Support Department for assistance.

Phone: [phone]
Fax: [phone]

E-mail: [e-mail]

618 Highway 74 South
Peachtree City, GA 30269
Attn: Hoshizaki Technical Support Department

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.

2

IMPORTANT

This manual should be read carefully before the appliance is serviced. Read
the warnings and guidelines contained in this manual carefully as they provide
essential information for the continued safe use, service, and maintenance of the
appliance. Retain this manual for any further reference that may be necessary.

CONTENTS

Important Safety Information ................................................................................................. 5

I. General Information ............................................................................................................ 8

A. Construction .................................................................................................................. 8

B. Refrigeration Flow Chart ............................................................................................. 10

II. Sequence of Operation and Service Diagnosis ................................................................11

A. Sequence of Operation Flow Charts ............................................................................ 11

1. Refrigerator .............................................................................................................11

2. Freezer .................................................................................................................. 12

B. Service Diagnosis ....................................................................................................... 13

1. Refrigerator ............................................................................................................ 15

2. Freezer .................................................................................................................. 19

C. Control Module Check ................................................................................................. 23

D. Thermistor Check ........................................................................................................ 24

E. Diagnostic Tables ........................................................................................................ 25

III. Controls and Adjustments ............................................................................................... 27

A. Control Module ............................................................................................................ 27

B. Temperature ............................................................................................................... 29

1. Default Settings ...................................................................................................... 29

2. Temperature Setpoint ............................................................................................ 29

3. Changing the Temperature Display Scale (°F or °C) ............................................. 29

C. Defrost ........................................................................................................................ 30

D. Alarm Safeties ............................................................................................................. 31

E. Safety Devices ............................................................................................................ 32

F. Mullion/Perimeter Heater ............................................................................................. 32

IV. Refrigeration Circuit and Component Service Information.............................................. 33

A. Service for Refrigerant Lines ....................................................................................... 35

B. Component Service Information .................................................................................. 38

C. Door Reversal ............................................................................................................. 38

V. Maintenance .................................................................................................................... 39

VI. Preparing the Appliance for Periods of Non-Use ............................................................ 40

VII. Disposal ......................................................................................................................... 41

3

VIII. Technical Information .................................................................................................... 42

A. Electrical and Refrigerant Data ................................................................................... 42

B. Wiring Diagrams .......................................................................................................... 43

1. R1A/R2A/F1A-FG/FGCL/FGCR/FS/FSJ/FSL/FSLJ/HG/HS/HSL,

PT1A-FG-FG/FS-FS/HS-HS .................................................................................. 43

2. F2A-FG/FS/HG/HS ............................................................................................... 44

3. PT2A-FG-FG/FS-FS/HS-HS ................................................................................. 45

4. R3A-FG/FGCL/FGCR/FS/FSCL/FSCR/HS/HG ..................................................... 46

5. F3A-FS/HS ............................................................................................................ 47

6. DT1A-HS ............................................................................................................... 48

7. DT2A-FS/HS .......................................................................................................... 49

4

Important Safety Information

Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, damage to the appliance, or damage to property.

DANGER

WARNING

NOTICE

IMPORTANT

Indicates a hazardous situation that, if not avoided, will result in
death or serious injury.

Indicates a hazardous situation that, if not avoided, could result
in death or serious injury.

Indicates a situation that, if not avoided, could result in damage
to the appliance or property.

Indicates important information about the use and care of the
appliance.

DANGER

Risk of Fire or Explosion

Flammable Refrigerant Used

• Follow handling instructions carefully
in compliance with U.S. government
regulations.

• Do not use mechanical devices to defrost.

• Do not puncture refrigerant tubing. Risk
of re or explosion due to puncture
of refrigerant tubing; follow handling
instructions carefully.

• Component parts shall be replaced with
like components.

• Servicing shall be done by factory
authorized service personnel to minimize
the risk of possible ignition due to incorrect
parts or improper service.

• Consult instruction manual/ service
manual before attempting to install or
service this product. All safety precautions
must be followed.

• Dispose of properly in accordance with
federal or local regulations.

• Do not place any potential ignition sources
in or near the appliance.

Risque De Feu Ou D'Explosion

Le Frigorigène Est Inammable

• Suivre attentivement les instructions
de manipulation conformément à la
réglementation gouvernementale.

• Ne pas utiliser d'appareils mécaniques
pour dégivrer le réfrigérateur.

• Ne pas perforer la tubulure contenant le
frigorigène. Risque de feu ou d'explosion
si la tubulure contenant le frigorigène
est perforée; suivre les instructions de
manutention avec soin.

• Les pièces des composants doivent être
remplacées par des pièces et accessoires
équivalents.

• L’entretien doit être effectué par le
personnel de service autorisé par le
fabricant an de minimiser les risques
d’inammation attribuables à l’installation
d’une pièce inadéquate ou à la mauvaise
exécution du service.

• Consulter le manuel du propriétaire/
guide de réparation avant de tenter une
réparation. Toutes les mesures de sécurité
doivent être respectées.

• Éliminer conformément aux règlements
fédéraux ou locaux.

• Ne placez aucune source d’inammation
potentielle dans ou près de l’appareil.

5

WARNING

The appliance should be destined only to
the use for which it has been expressly
conceived. Any other use should be
considered improper and therefore
dangerous. The manufacturer cannot be
held responsible for injury or damage
resulting from improper, incorrect, and
unreasonable use. Failure to install,
operate, and maintain the appliance
in accordance with this manual will
adversely affect safety, performance,
component life, and warranty coverage.

To reduce the risk of death, electric
shock, serious injury, or re, follow
basic precautions including the
following:

• Only qualied service technicians should
install and service the appliance.

• Wear appropriate personal protective
equipment (PPE) when servicing the
appliance.

• The appliance must be installed in
accordance with applicable national, state,
and local codes and regulations.

• Appliance is heavy. Use care when lifting
or positioning. Work in pairs when needed
to prevent injury or damage. Do not lift
using the top section or the doors/drawers.

• To reduce the risk of electric shock, do not
touch the plug with damp hands.

• Unplug the appliance before servicing.

• The appliance requires an independent
power supply of proper capacity. See the
nameplate for electrical specications.
Failure to use an independent power
supply of proper capacity can result in a
tripped breaker, blown fuse, damage to
existing wiring, or component failure. This
could lead to heat generation or re.

• THE APPLIANCE MUST BE
GROUNDED. The appliance is equipped

with a NEMA5-15 three-prong grounding
plug to reduce the risk of potential
shock hazards. It must be plugged into a
properly grounded, independent 3-prong
wall outlet. If the outlet is a 2-prong outlet,
it is your personal responsibility to have
a qualied electrician replace it with a
properly grounded, independent 3-prong
wall outlet. Do not remove the ground
prong from the power cord and do not use
an adapter plug. Failure to follow these
instructions may result in death, electric
shock, or re.

• Do not use an extension cord.

• Do not use an appliance with a damaged
power cord. The power cord should not be
altered, jerked, bundled, weighed down,
pinched, or tangled. Such actions could
result in electric shock or re. To unplug
the appliance, be sure to pull the plug, not
the cord, and do not jerk the cord.

• The GREEN ground wire in the factory­installed power cord is connected to the
appliance. If it becomes necessary to
remove or replace the power cord, be
sure to connect the power cord's ground
wire.

• Do not splash, pour, or spray water
directly onto or into the appliance. This
might cause short circuit, electric shock,
corrosion, or failure.

• Do not make any alterations to the
appliance. Alterations could result in
electric shock, injury, re, or damage to
the appliance.

• The appliance is not intended for use by
persons (including children) with reduced
physical, sensory, or mental capabilities,
or lack of experience and knowledge,
unless they have been given supervision
or instruction concerning use of the
appliance by a person responsible for
their safety.

6

WARNING, continued

• Children should be properly supervised
around the appliance.

• Do not climb, stand, or hang on the
appliance or doors or allow children or
animals to do so. Do not climb into the
appliance or allow children or animals to
do so. Death or serious injury could occur
or the appliance could be damaged.

• Be careful not to pinch ngers when
opening and closing the doors or when
handling food pans. Be careful when
opening and closing the doors when
children are in the area.

• Open and close the doors with care.
Opening the doors too quickly or forcefully
may cause injury or damage to the
appliance or surrounding equipment.

• Do not use combustible spray or place
volatile or ammable substances in or
near the appliance. They might catch re.

• Keep the area around the appliance clean.
Dirt, dust, or insects in the appliance
could cause harm to individuals or
damage to the equipment.

• Do not throw anything onto the shelves
or load any single shelf with more than
120lb. (54.5 kg) of product. They might fall
off and cause injury.

• The appliance is designed only for
temporary storage of food. Employ
sanitary methods. Use for any other
purposes (for example, storage of
chemicals or medical supplies such
as vaccine and serum) could cause
deterioration of stored items.

• Do not place any product on the oor of
the cabinet. All product must be placed on
properly installed shelves.

WARNING, continued

• Do not put warm or hot foods in the cabinet.
Let them cool rst, or they will raise the
cabinet temperature and could deteriorate
other foods in the cabinet or overload the
appliance.

• Food storage and handling must comply with
applicable codes and regulations.

• All foods should be wrapped in plastic lm
or stored in sealed containers. Otherwise
foods may dry up, pass their smells onto
other foods, cause frost to develop, result in
poor appliance performance, or increase the
likelihood of cross-contamination. Certain
dressings and food ingredients, if not
stored in sealed containers, may accelerate
corrosion of the evaporator, resulting in
failure.

• Do not store items near air outlets.
Otherwise, items may freeze up and
crack or break causing a risk of injury or
contamination of other food.

NOTICE

• Protect the oor when moving the appliance
to prevent damage to the oor.

• Keep ventilation openings, in the appliance
enclosure or in the built-in structure, clear of
obstruction.

• Do not allow the appliance to bear any
outside weight.

• To prevent deformation or cracks, do not
spray insecticide onto the plastic parts or let
them come into contact with oil.

• To avoid damage to the gasket, use only the
door handle when opening and closing.

• Do not block air inlets or outlets, otherwise
cooling performance may be reduced.

• Do not tightly pack the cabinet. Allow
some space between items to ensure
good air ow. Also allow space between
items and interior surfaces.

7

I. General Information

A. Construction

1. Solid Door Models

Condenser Fan Motor

Defrost Thermistor

Evaporator Fan

Condenser

Wick

Evaporator

Evaporator
Cover

Cabinet
Thermistor

Compressor

Power Cord
Thermostatic
Expansion Valve

Front Panel

Door Lock

Light

Door Switch

Control Module

Control Panel

Door

Door
Gasket

Model Shown: R1A-FS

8

2. Glass Door Models

Condenser Fan Motor

Condenser

Wick

Evaporator Fan

Compressor

Defrost Thermistor

Evaporator

Evaporator
Cover

Cabinet
Thermistor

Thermostatic Expansion Valve

Power Cord

Front Panel

24VDC Driver
Glass Door
Models

Door Lock

Model Shown: R2A-FG

Control Module

Control Panel

LED Lights
Glass Door
Models

Door

Door
Gasket

Model Shown: R2A-FG

9

B. Refrigeration Flow Chart

Condenser

High-Pressure Switch

Thermostatic
Expansion Valve

Defrost Heater and
Defrost Thermostat
(freezer only)

Condenser Fan

Evaporator Fans
(quantity depends on model)

Drier

Compressor

Defrost
Thermistor

Evaporator

Cabinet Thermistor

Condensate Pan

10

II. Sequence of Operation and Service Diagnosis

A. Sequence of Operation Flow Charts

1. Refrigerator

DTh warms to

44°F (6.6°C) or

1-hr maximum

defrost timer

2-hr continuous compressor run

defrost timer terminates

terminates

Comp energized

ConFM energized

EvapFM energized

DTh in control

5-min.

minimum

defrost

5. Defrost Termination

2-hr cumulative compressor run or

4. Defrost

EvapFM energized

Comp de-energized

ConFM de-energized

CTh warms

to 3°F (1.7°C)

above setpoint

CTh cools to

3°F (1.7°C)

below setpoint.

Factory default

38°F (3°C)

2-min. Comp off

2. Cool Down Achieved

Refrigerator Sequence Flow Chart

timer starts

a) EvapFM de-energizes when door is opened on -FS models and when upper door is opened on -HS models.

b) 2-min. minimum Comp on timer starts when Comp energizes.

c) 2-min. minimum Comp off timer starts when Comp de-energizes.

d) 5-min. minimum defrost time.

e) 1-hr. maximum defrost time.

f) "dEF" displayed during defrost.

Comp de-energized

ConFM de-energized

EvapFM de-energized

(60-sec. delay

before de-energized)

Note:

CTh in control

g) 15-minute temperature delay timer starts when Comp/ConFM energize.

3. Cool Down Restart

2-min. Comp on

timer starts

Comp energized

ConFM energized

EvapFM energized

1. Startup/Cool Down

Legend:

Comp-compressor

ConFM-condenser fan motor

CTh-cabinet thermistor

DTh-defrost thermistor

EvapFM-evaporator fan motor

MH-mullion heater

Cycle Steps

Slight

Delay at

Startup

MH energized

Power on

11

2. Freezer

DTh warms to 77°F (25°C)

5. Defrost Termination

5-hr. cumulative Comp run or

4. Defrost

or 1-hr maximum defrost

4-hr. continuous run defrost

timer terminates

timer terminates

DTh in

control

5-min.

minimum

defrost

DH de-energized

DH energized

*After Drip Time Delay:

Comp de-energized

Comp energized

ConFM de-energized

ConFM energized

EvapFM de-energized

EvapFM energized

*(Once DTh reaches 15°F (-9°C)

or 4-min. EvapFM terminates,

whichever comes rst)

CTh warms

to 3°F (1.7°C)

above setpoint

Freezer Sequence Flow Chart

CTh cools to

3°F (1.7°C)

below setpoint.

Factory default

-2°F (-19°C)
2-min. Comp off

Startup

CTh in control

2-min. Comp on

timer starts

timer starts

Power on

Comp de-energized

Comp energized

DrH energized

ConFM de-energized

ConFM energized

MH energized

EvapFM de-energized

EvapFM energized

PH energized

(60-sec. delay

after Comp

de-energized)

a) EvapFM de-energizes when door is opened on -FS models and when upper door is opened on -HS models.

b) 2-min. minimum Comp on timer starts when Comp energizes.

c) 2-min. minimum Comp off timer starts when Comp de-energizes.

d) 5-min. minimum defrost time.

e) 1-hr. maximum defrost time.

f) "dEF" displayed during defrost.

g) 3-min. Comp/ConFM delay timer starts when defrost termination temperature is met.

h) 4-minute EvapFM delay timer starts when Comp/ConFM delay timer terminates

MH-mullion heater

i) 15-minute temperature delay timer starts when EvapFM energizes

PH-perimeter heater

Note: *Delays

(30-sec. delay

after Comp

energized)

Legend:

Comp-compressor

ConFM-condenser fan motor

CTh-cabinet thermistor

DH-defrost heater

DrH-drain heater

DTh-defrost thermistor

EvapFM-evaporator fan motor

2. Cool Down Achieved

1. Startup/Cool Down

3. Cool Down Restart

5-hr. cumulative Comp run

time defrost timer starts

Slight

Delay at

12

B. Service Diagnosis

DANGER

Risk of Fire or Explosion

Flammable Refrigerant Used

• Follow handling instructions carefully
in compliance with U.S. government
regulations.

• Do not use mechanical devices to defrost.

• Do not puncture refrigerant tubing. Risk
of re or explosion due to puncture
of refrigerant tubing; follow handling
instructions carefully.

• Component parts shall be replaced with
like components.

• Servicing shall be done by factory
authorized service personnel to minimize
the risk of possible ignition due to
incorrect parts or improper service.

• Consult instruction manual/service manual
before attempting to install or service this
product. All safety precautions must be
followed.

• Dispose of properly in accordance with
federal or local regulations.

• Do not place any potential ignition sources
in or near the appliance.

Risque De Feu Ou D'Explosion

Le Frigorigène Est Inammable

• Suivre attentivement les instructions
de manipulation conformément à la
réglementation gouvernementale.

• Ne pas utiliser d'appareils mécaniques
pour dégivrer le réfrigérateur.

• Ne pas perforer la tubulure contenant le
frigorigène. Risque de feu ou d'explosion
si la tubulure contenant le frigorigène
est perforée; suivre les instructions de
manutention avec soin.

• Les pièces des composants doivent être
remplacées par des pièces et accessoires
équivalents.

• L’entretien doit être effectué par le
personnel de service autorisé par le
fabricant an de minimiser les risques
d’inammation attribuables à l’installation
d’une pièce inadéquate ou à la mauvaise
exécution du service.

• Consulter le manuel du propriétaire/
guide de réparation avant de tenter une
réparation. Toutes les mesures de sécurité
doivent être respectées.

• Éliminer conformément aux règlements
fédéraux ou locaux.

• Ne placez aucune source d’inammation
potentielle dans ou près de l’appareil.

WARNING

• The appliance should be diagnosed and repaired only by qualied service
personnel to reduce the risk of death, electric shock, serious injury, or re.

• Wear appropriate personal protective equipment (PPE) when servicing the
appliance.

• Risk of electric shock. Use extreme caution and exercise safe electrical practices.

• Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.

• Appliance is heavy. Use care when lifting or positioning. Work in pairs when
needed to prevent injury or damage.

• Make sure all food zones are clean after the appliance is serviced.

13

NOTICE

• This appliance is not intended for outdoor use.

• Normal operating ambient temperature:
– Refrigerators and Solid Door Freezers 45°F to 100°F (7°C to 38°C)
– Glass Door Freezers 45°F to 80°F (7°C to 27°C)
Operation of the appliance, for extended periods, outside of this normal
temperature range may affect appliance performance.

• The appliance must not be located next to ovens, grills, or other high heat
producing equipment.

• The appliance must not be located in a corrosive environment.

• Minimum Clearance:

Models Side Top Rear

Reach-In Refrigerators and Freezers

Except 2-Section Freezers

2-Section Freezers 0" (0 cm) 10" (25 cm) 3" (8 cm)

The diagnostic procedure is a sequence check that allows you to diagnose the electrical
system and components. Before proceeding, check for correct installation and proper
voltage per nameplate. Always choose a neutral (W) to establish a good neutral
connection when checking high voltages. If the display is in alarm, see "III.D. Alarm
Safeties."

0" (0 cm) 0" (0 cm) 3" (8 cm)

IMPORTANT

The maximum allowable voltage variation is ±10 percent of the nameplate rating.
115VAC is used as a reference voltage when checking voltage to components.
Voltage may vary depending on power supply.

1. Factory Default Settings:
a) Temperature Setpoint:

Model Auxiliary Code Temperature Setpoint

Refrigerator All 38°F (3°C)
Freezer All -2°F (-19°C)

b) Temperature Display Scale: °F.

For further details, see "II.C. Control Module Check" or "III. Controls and Adjustments."

• There is a minimum 2-min. Comp on time and 2-min. Comp off time.

1) Unplug the appliance from the electrical outlet.

2) Remove the front panel.

3) Plug the appliance back into the electrical outlet.

4) Conrm 115VAC at CM 2 (L) (BK) to neutral (W).

14

1. Refrigerator

5) Startup/Cool Down–MH and PH energize. There is a slight delay, Comp, ConFM, and
EvapFM energize. Cabinet temperature appears on display and 2-hr. defrost timer
starts. Note, if DTh is above 50°F (10°C) EvapFM is de-energized.

a) MH Diagnosis: MH energizes at startup. If 115VAC is present, check amp draw of

MH. If an amp reading is not present, check the continuity of MH. If defective, replace
MH.

b) EvapFMDiagnosis: Conrm that EvapFM(s) energize. If not, conrm DTh is at 50°F

(10°C) or lower, doors are closed and DS engaged, check DS continuity.
If DTh is above 50°F (10°C), wait for evaporator to cool down. If DS is engaged and
contacts are open, replace DS. If DS is engaged and contacts are closed, check for
115VAC at CM 5 (F) dark blue (DBU) wire to neutral white (W) wire. If 115VAC is not
present, replace CM. If 115VAC is present, check EvapFM blades for binding and
EvapFM continuity.

c) Solid Door Cabinet Light Diagnosis: LED(s) are activated from door switch. Open

the door (upper on HS/HG), conrm LED(s) energizes. If not, with door open, check
for 5 to 12VDC at CM S4 brown (BR) to CM S4 blue (BU). If 5 to 12VDC is not
present at CM S4 brown (BR) to CM S4 blue (BU), conrm 115VAC power supply
to CM at terminals 2 (L) black (BK) to 3 (N) white (W). If 115VAC is present, and
LED(s) are off, check DS continuity. If DS is disengaged (open) and contacts are
closed, replace DS. IfDS is disengaged (open) and contacts are open, check for
115VAC from CM 6 (LED) (Y) to a neutral (W). If 115VAC is not present, replace CM.
If 115VAC is present at CM 6 (LED) (Y) to a neutral (W) and LED(s) are not on, check
for 24VDC at DCD black (BK) wire to DCD red (R) wire. If 24VDC is not present,
check continuity of DCD driver. If open, replace DCD driver. If 24VDC is present
and LED(s) are not on, check wiring harness and wiring connections from DCD to
LED(s). Ifconnections are good and LED(s) are not on, replace LED(s).

d) Glass Door Cabinet Light Diagnosis: LED(s) are activated from control module

light switch. Glass door models feature lights that are controlled by the Standby/Light
control button located on the control module. Press the standby/light button quickly
to turn the light on or off. If LED(s) fail to turn on, check for 115VAC from CM 6 (LED)
(Y) to a neutral (W). If 115VAC is not present at CM 6 (LED) (Y)to a neutral (W),
replace CM. If 115VAC is present at CM 6 (LED) (Y) to a neutral (W) and LED(s) are
not on, check for 24VDC at DCD black (BK) wire to DCD red (R) wire. If 24VDC is
not present, check continuity of DCD driver. If open, replace DCD driver. If 24VDC is
present and LED(s) are not on, check wiring harness and wiring connections from
DCD to LED(s). Ifconnections are good and LED(s) are not on, replace LED(s).

e) CM Diagnosis: Cabinet temperature appears on display. If not, check for 115VACat

CM 2 (L) (BK) to CM 3 (N) (W). If 115VAC is not present, check power cord
connections and breaker/fuse. Conrm wiring connections are secure for both
CM 2 (L) (BK) (power supply) and CM 3 (N) (W). If 115VAC is present and display is
off, replace CM.

15