Hoshizaki DCM-500BWH, DCM-500BAH User Manual

HoshizakiHoshizaki America, Inc.

“A Superior Degree

of Reliability”

www.hoshizaki.com

Cubelet Icemaker / Dispenser

Models

DCM-500BAH

DCM-500BAH-OS

DCM-500BWH

DCM-500BWH-OS

SERVICE MANUAL

Number: 73165

Issued: 7-30-2008

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: [phone] Technical Service [phone]

Fax: [phone]

[phone]

E-mail: [e-mail]

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 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......................................................................................................................	5
A. Icemaker........................................................................................................................	5
1. DCM-500BAH...........................................................................................................	5
2. DCM-500BAH-OS....................................................................................................	6
3. DCM-500BWH.........................................................................................................	7
4. DCM-500BWH-OS...................................................................................................	8
II. General Information............................................................................................................	9
A. Construction...................................................................................................................	9
B. Ice Making Unit.............................................................................................................	11
C. Sequence of Operation................................................................................................	12
1. Fill Cycle.................................................................................................................	12
2. Ice Purge Cycle (60 seconds)................................................................................	12
3. Freeze Cycle..........................................................................................................	12
4. Drain Cycle.............................................................................................................	12
5. Shutdown...............................................................................................................	12
D. Control Board...............................................................................................................	14
1. Control Board Layout..............................................................................................	15
a) DCM-500BAH, DCM-500BWH..........................................................................	15
b) DCM-500BAH-OS, DCM-500BWH-OS.............................................................	16
2. Features.................................................................................................................	17
3. Controls and Adjustments .....................................................................................	18
4. Control Board Check Procedure.............................................................................	18
E. Float Switch.................................................................................................................	20
III. Technical Information.......................................................................................................	21
A. Water Circuit and Refrigeration Circuit.........................................................................	21
B. Wiring Diagrams..........................................................................................................	23
1. DCM-500BAH, DCM-500BWH ..............................................................................	23
2. DCM-500BAH-OS, DCM-500BWH-OS .................................................................	24
C. Sequence of Electrical Circuit – Ice Making................................................................	25
1. Fill Cycle ................................................................................................................	25
2. Ice Purge Cycle .....................................................................................................	26
3. Freeze Cycle .........................................................................................................	27
4. 12 Hour Drain Cycle / Drain Switch........................................................................	28
5. Shutdown...............................................................................................................	29
6. Low Water Safety ..................................................................................................	30
7. High Pressure Switch .............................................................................................	31
D. Sequence of Electrical Circuit – Dispensing ...............................................................	32
1. Continuous Dispense..............................................................................................	32
2. Portion Dispense....................................................................................................	33

3

E. Performance Data........................................................................................................	34
1. DCM-500BAH(-OS)................................................................................................	34
2. DCM-500BWH(-OS)...............................................................................................	35
IV. Service Diagnosis............................................................................................................	36
A. Diagnostic Procedure...................................................................................................	36
B. Ice Production Check...................................................................................................	37
C. Diagnostic Charts........................................................................................................	38
1. No Ice Production...................................................................................................	38
2. Low Ice Production.................................................................................................	41
3. Other......................................................................................................................	42
4. Dispensing.............................................................................................................	43
5. Opti Serve (OS) Sensors.......................................................................................	44
V. Removal and Replacement of Components.....................................................................	46
A. Service for Refrigerant Lines.......................................................................................	46
1. Refrigerant Recovery..............................................................................................	46
2. Brazing...................................................................................................................	46
3. Evacuation and Recharge (R-404A)......................................................................	47
B. Removal and Replacement of Compressor.................................................................	48
C. Removal and Replacement of Expansion Valve..........................................................	49
D. Removal and Replacement of Evaporator Assembly Components..............................	50
1. Upper Bearing Wear Check ...................................................................................	51
2. Removal and Replacement of Extruding Head......................................................	51
3. Removal and Replacement of Auger......................................................................	52
4. Removal and Replacement of Evaporator..............................................................	52
5. Removal and Replacement of Mechanical Seal and Lower Housing ....................	54
6. Removal and Replacement of Gear Motor.............................................................	55
E. Removal and Replacement of Self-Contained Air-Cooled Condenser.........................	56
F. Removal and Replacement of Water-Cooled Condenser.............................................	57
G. Removal and Replacement of Water Regulating Valve Water Cooled Model Only....	58
H. Adjustment of Water Regulating Valve - Water-Cooled Model Only.............................	59
I. Removal and Replacement of Fan Motor......................................................................	59
J. Removal and Replacement of Inlet or Dispensing Water Valve....................................	60
K. Removal and Replacement of Drain Valve...................................................................	60
L. Removal and Replacement of Dispensing System......................................................	61
1. Dispensing Auger and Agitator................................................................................	61
2. Dispensing or Agitating Motor................................................................................	61
VI. Cleaning and Maintenance.............................................................................................	63
A. Cleaning and Sanitizing Instructions............................................................................	63
1. Water System..........................................................................................................	64
a) Cleaning Solution................................................................................................	64
b) Cleaning Procedure.............................................................................................	64
c) Sanitizing Solution...............................................................................................	65
d) Sanitizing Procedure - Following Cleaning Procedure ........................................	65
2. Dispensing Components........................................................................................	65
a) Cleaning Solution................................................................................................	65
b) Sanitizing Solution..............................................................................................	65
c) Cleaning and Sanitizing Procedure.....................................................................	65
B. Maintenance................................................................................................................	67
C. Preparing the Icemaker for Long Storage....................................................................	68

4

I. Specifications

A. Icemaker

1. DCM-500BAH

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)
SHAPE OF ICE		100		340 (154)	323 (147)	*304 (138)
		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

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

5

2. DCM-500BAH-OS

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)
SHAPE OF ICE		100		340 (154)		323 (147)	*304 (138)
		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.

6

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				WATER TEMP. (°F)
PER 24 HR.		Temp. (°F)			50		70		90
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)
SHAPE OF ICE		100			472	(214)	464	(210)	* 428	(194)
		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			70/50°F
ELECTRIC	W (kWH/100 lbs.)	967 (4.7)			991 (4.1)
POTABLE WATER		60 (12)			68 (12)
WATER - COOLED CONDENSER		352 (71.2)			251 (44.3)
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

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

7

4. DCM-500BWH-OS

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			WATER TEMP. (°F)
PER 24 HR.		Temp. (°F)		50			70		90
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
SHAPE OF ICE		100		472	214		464	210	* 428	194
		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		70/50°F
ELECTRIC	W (kWH/100 lbs.)	930 (4.8)		985 (4.0)
POTABLE WATER		56 (12)		65 (12)
WATER - COOLED CONDENSER		465 (100)		285 (52)
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

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

8

II. General Information

A. Construction

1. DCM-500BAH(-OS)

		Expansion Valve
	Spout A	Spout B
Evaporator Assembly		Drain Water Valve
Inlet Water Valve		Storage Bin
Float Switch
Reservoir
Control Box		Agitator

Power Switch

Ice Dispensing

Auger

Door Switch

Gear Motor

Control Switch

Dispense Mode Switch

Air-Cooled

Condenser

Shutter Assembly

Drier

Agitating Motor

Dispensing Motor

Compressor

Dispensing Water

Valve

Spout Cover

9

2. DCM-500BWH(-OS)

Spout A Expansion Valve

	Spout B
Evaporator Assembly	Drain Water Valve

Inlet Water Valve

Float Switch

Reservoir

Control Box

Power Switch

Door Switch

Gear Motor

Control Switch

Dispense Mode Switch

Shutter Assembly

Water-Cooled Drier

Condenser

Storage Bin

Agitator

Ice Dispensing

Auger

Agitating Motor

Dispensing Motor

Compressor

Dispensing Water

Valve

Spout Cover

10

B.Ice Making Unit

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

Extruding Head and	Cubelet Cutter
Upper Bearing
	Allen Head Cap Screw
Auger	Washer
Cylinder
Evaporator
Insulation
Mechanical-Seal
O-Ring
Spline Coupling	Allen Head Cap Screw
Gear Motor	with Washer
	Housing and
	Lower Bearing
	Hex Head Bolt
	with Washer
	11

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

12

DCM-500BAH(-OS), DCM-500BWH(-OS) Sequence Flow Chart and Component Operation

4. 12 Hour Drain Cycle

DV opens for 20 minutes every 12 hours See "3. 12 Hour Drain Cycle" below.

1. Fill Cycle

2. Ice Purge Cycle

3. Freeze Cycle

1. Startup
Power switch "ON"									Refill
									(90 seconds)
Control switch in "ICE"
				60 seconds

Low Water Safety

If refill > 90 sec. FT, 150 second shutdown sequence begins

150 sec. Shutdown Sequence

90 seconds		60 seconds

13

WV on

LF/S closed

Comp on

UF/S open

LF/S closed

UF/S open

UF/S open

UF/S closed (WV off)

FMS on

LF/S open (WV on)

UF/S closed (WV off)

FT exceeded

WCR on

WCR continues

WCR off

WCR on

Comp continues

WV off

GM continues

FT started (90 sec.)

FT off (90 sec.)

FMS continues

GM on

GMPR continues WV on

WV off

GM continues

GMPR on

Comp continues

Comp continues

GMPR continues

FMS continues

FMS continues

WV continues

GM continues

GM continues

GMPR continues

GMPR continues

2.Shutdown & Restart

3.12 Hour Drain Cycle Shutdown & Restart

1. Bin Full

2. Ice Purge Cycle

3. Icemaker is Off

4. Ice Level Lowered

150

See "1. Fill Cycle" above

seconds

90 seconds

60 seconds

1. Drain Cycle initiates

2. Ice Purge Cycle

3. Drain Cycle

4. 12 hour DC - Restart

DV on for 20 minutes

See "1. Fill Cycle" above

BC open or DC starts

Comp off

GM off

BC closed

Comp continues

FMS off

GMPR off

or

FMS continues

GM continues

DV on (DC only)

20 Min. DT off (DC only)

GM continues

GMPR continues

DV off (DC only)

GMPR continues

12 hour DT reset (DC only)

Components Energized when the Control Switch is in the "DRAIN" Position

The "DRAIN" position on the control switch is used when cleaning and sanitizing the unit. This allows cleaner and sanitizer to drain from the reservoir and evaporator assembly. When switching to the "DRAIN" position during the freeze cycle, the drain valve does not energize until the 150 second shutdown sequence terminates (2. Shutdown & Restart).

Note: To bypass the 150 second shutdown sequence, move the power switch to the "OFF" position, place the control switch in the "DRAIN" position, then move the power switch back to the "ON" position.

Comp off	GM off
FMS off	GMPR off
WV continues	WV continues until
GM continues	UF/S closes
GMPR continues

Legend:

BC - bin control Comp - compressor DC - drain cycle

DT - drain timer DV - drain valve

FMS - self-contained fan motor FT - fill timer (low water safety) 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

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.

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1.Control Board Layout

a)DCM-500BAH, DCM-500BWH

			Dispensing
	Flush Switch		Components	Bin Control,
	Must be left in the "P" position,		See "III.
				Control
	otherwise the internal drain	High	B. Wiring
				Switch,
	timer will not operate.	Pressure	Diagrams"
				Low Water	10.5V
		Switch	for details.
				Safety
	Counter Reset Button (not				Transformer
	used in this application)

	Portion Control	Microprocessor (board revision level		"POWER" LED
	Timer	indicated by last 2 digits on label)
				(lights when
		"DM" LED
				power is supplied
		(X4 Relay)		to the board)
		Shutter Solenoid,	"AM" LED
		Dispensing Auger	(X3 Relay)
		Motor	Agitating Motor

	"COMP" LED	"GM" LED
	(X2 Relay)
		(X1 Relay)
	Compressor,
		Gear Motor
	Fan Motor
	"FLUSH" LED
	(X5 Relay)
	Drain Valve

	24V Supply Out		Gear Motor
	115V In	115V In
			Protect Relay	115V In
	Drain Valve 24V In
			Circuit
	24V Out			Gear Motor
		Agitating Motor
	Dispensing Motor			115V Out
	115V Out	115V Out

Control Board

Part Number 2A1592-01

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

Flush Switch

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

Counter Reset Button (not used in this application)

		Bin Control,
		Control Switch,
	Dispensing Components
	See "III.B. Wiring Diagrams"	Low Water Safety
		High	10.5V
	for details.
		Pressure	Transformer
		Switch

	Portion Control	Microprocessor (board revision level		"POWER" LED
	Timer			(lights when
		indicated by last 2 digits on label)
				power is supplied
	"WTR" LED	"ICE" LED	"AM" LED	to the board)
	(X5 Relay)	(X4 Relay)	(X3 Relay)	"GM" LED
	Dispensing	Shutter Solenoid,	Agitating Motor
				(X1 Relay)
	Water Valve	Dispensing Auger
			"COMP" LED	Gear Motor
		Motor
			(X2 Relay)
			Compressor,
			Fan Motor
	"FLUSH" LED
	(X6 Relay)
	Drain Valve

	24V Supply Out				Gear Motor
			24V In 115V In
	Drain Valve	24V In		115V In	Protect Relay	115V In
					Circuit
	24V Out					Gear Motor
	Dispensing		Dispensing Motor	Agitating Motor
						115V Out
	Water Valve		115V Out	115V Out

24V Out

Control Board

Part Number 2A2649-01

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2. Features

The control board provides the following safeguards:

•Provides component protection during low water supply.

•Purges remaining ice in the evaporator at startup and shutdown.

•Provides short cycle protection for the compressor.

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		Time LEDs are	Frequency LEDs are
		Components		On	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,		N/A	N/A
		FMS
Drain Valve (X6)	FLUSH	DV		20 Minutes	Every 12 Hours
		Dispensing
Relay	LED	Energized		Time LEDs are	Frequency LEDs are
		Component		On	On
	Push Button
Ice Dispense (X4)	DM	IDM		60 seconds	N/A
	Opti Serv			maximum
	ICE
					Every 12 seconds of
Agitating Motor (X3)	AM	AM		.6 seconds	accumulative dispense
					time
Water Dispense (X5)	WTR	WTR		N/A	N/A
(Opti Serv Only)

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

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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.

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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."

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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)

Magnet (towards top)

Upper Float (blue)

Spring Retainer Clip

Magnet (towards top)

Lower Float (white)

Plastic Retainer Clip

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III. Technical Information

A.Water Circuit and Refrigeration Circuit

1.DCM-500BAH(-OS)

Inlet

Water

Valve

Water Supply

Float Switch

Water Level

Reservoir

Evaporator

Overflow

Gear Motor

Fan

Air-Cooled

Condenser

Access

Valve

Refrigeration Circuit

Water Circuit

Spout

Drier

Expansion

Valve

To Drain

Drain

Valve

Dispensing

Water Valve

High

Pressure

Switch

Compressor Access

Valve

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