Hoshizaki HWR96A, HUR96A, HWF40AD, HUF68A, HUF40AD Service Manual
...
Hoshizaki America, Inc.
Hoshizaki
Commercial Refrigerators & Freezers
Undercounter & Worktop Series
“A Superior Degree
of Reliability”
www.hoshizaki.com
Models
Refrigerators
HUR40A(-D) HWR40A(-D)
HUR68A(-D) HWR68A(-D)
HUR96A(-D) HWR96A(-D)
Freezers
HUF40A(-D) HWF40A(-D)
HUF68A(-D) HWF68A(-D)
SERVICE MANUAL
Number: 73123
Issued: 2-4-2005
Revised: 9-30-2008
IMPORTANT
Only qualied service technicians should attempt to service or maintain this
unit. No such service or maintenance should be undertaken until the technician
has thoroughly read this Service Manual.
Hoshizaki provides this manual primarily to assist qualied service technicians in the
service and maintenance of the unit.
Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call, write or send an e-mail message to the Hoshizaki Technical
Support Department for assistance.
HOSHIZAKI AMERICA, INC.
618 Highway 74 South
Peachtree City, GA 30269
Attn: Hoshizaki Technical Support Department
Phone: 1-800-233-1940 Technical Support
(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:
•ModelNumber__________________________
•SerialNumber__________________________
•Completeanddetailedexplanationoftheproblem.
ENERGY STAR
®
Products earning the ENERGY STAR prevent greenhouse gas emissions by meeting strict
energy efficiency guidelines set by the U.S. Environmental Protection Agency and the
U.S. Department of Energy. Several models of Hoshizaki undercounters have earned the
ENERGY STAR. To easily determine if your unit has earned the ENERGY STAR, see the
nameplate attached to the right wall on the inside of the cabinet.
2
Please review this manual. It should be read carefully before the unit is serviced or
maintenance operations are performed. Only qualied service technicians should service
and maintain the unit. This manual should be made available to the technician prior to
service or maintenance.
CONTENTS
I. Specications ...................................................................................................................... 5
A. Nameplate Ratings ........................................................................................................ 5
B. Dimensions ................................................................................................................... 5
1. HUR40A, HUF40A ................................................................................................... 6
1a. HUR40A-D, HUF40A-D ......................................................................................... 6
2. HWR40A, HWF40A ................................................................................................. 7
2a. HWR40A-D, HWF40A-D ........................................................................................ 7
3. HUR68A, HUF68A .................................................................................................. 8
3a. HUR68A-D, HUF68A-D ......................................................................................... 8
4. HWR68A, HWF68A ................................................................................................. 9
4a. HWR68A-D, HWF68A-D ........................................................................................ 9
5. HUR96A ................................................................................................................ 10
5a. HUR96A-D ........................................................................................................... 10
6. HWR96A ................................................................................................................11
6a. HWR96A-D ...........................................................................................................11
II. General Information ........................................................................................................ 12
A. Construction ................................................................................................................ 12
B. Sequence of Operation and Timing Charts ................................................................. 13
1. Refrigerators – Continuous Operating Mode ......................................................... 13
2. Freezers – Continuous Operating Mode .............................................................. 15
3. Refrigerators – Energy Saving Operating Mode ................................................... 17
4. Freezers – Energy Saving Operating Mode .......................................................... 19
C. Control Board .............................................................................................................. 21
1. Start-Up Delay........................................................................................................ 21
2. Control Board Layout ............................................................................................. 22
D. Settings and Diagnostics ............................................................................................. 23
1. Gaining Access to Settings and Diagnostics .......................................................... 23
2. Temperature Display .............................................................................................. 24
a) Switching the Display Between Fahrenheit and Celsius (F5) .......................... 24
b) Adjusting the Setpoint Temperature ................................................................. 24
c) Cabinet Temperature Correction (calibration factor) ......................................... 25
3. Settings and Diagnostics Menu ............................................................................. 26
a) Defrost Interval (F0) ......................................................................................... 27
b) Defrost Termination Temperature (F1) ............................................................. 27
c) Setpoint Temperature Differential (F2).............................................................. 28
d) High Temperature Alarm Delay Time (F3) ........................................................ 29
e) Low Temperature Alarm Delay Time (F4) ......................................................... 29
f) Temperature Display Scale (F5) ........................................................................ 30
g) Alarm History (F6) ............................................................................................ 30
h) Compressor Run Time (F7) ............................................................................. 31
3
4. Operating Modes ................................................................................................... 31
a) Continuous ....................................................................................................... 32
b) Energy Saving .................................................................................................. 32
c) Automatic Corrections Made During Energy Saving Operating Mode .............. 32
E. Perimeter Frame Heater .............................................................................................. 32
III. Service Diagnosis ........................................................................................................... 33
A. Alarm Codes ............................................................................................................... 33
1. Alarm Display Priority ............................................................................................. 34
2. Alarm Details and Countermeasures ..................................................................... 35
a. High Temperature Alarm (E1) ........................................................................... 35
b. Low Temperature Alarm (E2) ............................................................................ 36
c. Defrost Alarm (E3) ............................................................................................ 37
d. High Pressure Alarm (E4) ................................................................................. 37
e. Clogged Filter Alarm (E7) ................................................................................. 38
f. Defrost Temperature Sensor Malfunction Alarm (E8) ........................................ 39
g. Clogged Filter Sensor Malfunction Alarm (E9) ................................................. 40
h. Control Board Error Alarms (EA and ED) ......................................................... 41
B. Diagnosis Chart .......................................................................................................... 42
C. Thermistor Check ........................................................................................................ 45
IV. Removal and Replacement of Components ................................................................... 46
A. Service for Refrigerant Lines ....................................................................................... 46
1. Refrigerant Recovery ............................................................................................. 46
2. Brazing .................................................................................................................. 46
3. Evacuation and Recharge .................................................................................... 47
B. Removal and Replacement of Refrigeration Unit ........................................................ 48
C. Removal and Replacement of Compressor ................................................................ 48
D. Removal and Replacement of Evaporator ................................................................... 49
E. Removal and Replacement of Capillary Tube / Suction Line Assembly ...................... 51
F. Removal and Replacement of Thermistors .................................................................. 52
G. Removal and Replacement of Door Gasket ............................................................... 53
H. Removal and Replacement of Defrost Heater ............................................................. 53
I. Removal and Replacement of Control Board ............................................................... 54
J. Removal and Replacement of Fan Motors ................................................................... 55
K. Door Re-Hinging and Drawer Conversion ................................................................... 55
V. Cleaning and Maintenance Instructions ........................................................................... 56
A. Cleaning ...................................................................................................................... 56
B. Maintenance ................................................................................................................ 57
VI. Wiring Diagrams ............................................................................................................ 58
A1. HUR40A, HWR40A (auxiliary code Q5 and earlier) .................................................. 58
A2. HUR40A(-D), HWR40A(-D) (auxiliary code Q6 and later) ....................................... 59
B. HUF40A(-D), HWF40A(-D) ......................................................................................... 60
C1. HUR68A, HWR68A (auxiliary code Q5 and earlier) .................................................. 61
C2. HUR68A(-D), HWR68A(-D) (auxiliary code Q6 and later) ........................................ 62
D. HUF68A(-D), HWF68A(-D) ......................................................................................... 63
E. HUR96A(-D), HWR96A(-D)......................................................................................... 64
4
I. Specications
A. Nameplate Ratings
Design Pressure
(PSIG)
Model AC Supply Voltage Amperes HI LO 404A 134a
HUR40A(-D), HWR40A(-D) 115/60/1 5.0 240 120 15.2
HUR68A(-D), HWR68A(-D) 115/60/1 5.0 240 120 15.2
Refrigerant
(oz.)
HUR96A(-D), HWR96A(-D) 115/60/1 6.0 240 120 15.2
HUF40A(-D), HWF40A(-D) 115/60/1 5.5 450 250 14.1
HUF68A(-D), HWF68A(-D) 115/60/1 10.0 450 250 13.0
Undercounter Model Names
The undercounter models covered in this service manual initially had different model
names. If you have a unit with an auxiliary code of N-6 and a serial number ending in "H",
refer to the table below.
Model Name on
Nameplate
UR1-SSB HUR40A
UR2-SSB HUR68A
Current
Name
UF1-SSB HUF40A
UF2-SSB HUF68A
B. Dimensions
Door Opening mm Total Refrigerated
Model
HUR40A(-D), HWR40A(-D),
HUF40A(-D), HWF40A(-D)
HUR68A(-D), HWR68A(-D),
HUF68A(-D), HWF68A(-D)
HUR96A(-D), HWR96A(-D) 29.1 26.6 12
Width Height
570.2 616.2
Volume ft
18.8 1 7. 1 8
3
8.5 7. 6 4
Total Shelf
Space ft
2
Hotel Pan
Capacity (-D)
5
1. HUR40A, HUF40A
Units: mm (in.)
1a. HUR40A-D, HUF40A-D
6
2. HWR40A, HWF40A
Units: mm (in.)
2a. HWR40A-D, HWF40A-D
7
3. HUR68A, HUF68A
Units: mm (in.)
3a. HUR68A-D, HUF68A-D
8
4. HWR68A, HWF68A
Units: mm (in.)
4a. HWR68A-D, HWF68A-D
9
5. HUR96A
Units: mm (in.)
5a. HUR96A-D
10
6. HWR96A
Units: mm (in.)
6a. HWR96A-D
11
II. General Information
A. Construction
Hoshizaki undercounters feature a cartridge-type refrigeration unit that can be removed
without taking off the top and side panels.
Front Panel
Evaporator Assembly
Evaporator Case
Side Panel
Evaporator Case Cover
Defrost Thermostat
Defrost Heater
Compressor
Capillary Tube/Suction
Line Assembly
Thermal Fuse
Evaporator Case Cover
Control Box
Access Valve (Low-Side)
Condenser
Condenser Fan Motor
Compressor Base
Defrost Thermistor
Evaporator Shroud
Cabinet Thermistor
Evaporator Fan Motor
Evaporator
Evaporator Case
12
B. Sequence of Operation and Timing Charts
For details on operating modes, see "II.D.4. Operating Modes."
1. Refrigerators – Continuous Operating Mode
a) Sequence of Operation
POWER ON
Board Self Check
1. Frame heater(s) on
2. Evaporator fan(s) on
Cycle On (Cut-on
temperature reached)
[Minimum 2 minutes]
1. Compressor start-up
2. Condenser fan start-up
Continue as
normal cycling
2-minute Delay
1. Compressor start-up
2. Condenser fan start-up
Defrost Start
Preprogrammed time interval
1. Compressor off
2. Evaporator fan(s) off
3. Frame heater(s) off (Q6 and later)
4. Condenser fan off
5. Defrost heater on
6. "dF" displayed
Cycle Off (Cut-out
temperature reached)
[Minimum 2 minutes]
1. Compressor off
2. Condenser fan off
Defrost End
Defrost thermistor
reaches defrost
termination temperature,
or defrost timer reaches
1 hour
Defrost heater off
Five minutes after
defrost heater off
1. Compressor on
2. Condenser fan on
Five minutes after
compressor start-up
1. Evaporator fan(s) on
2. Frame heater(s) on
(Q6 and later)
One minute after evaporator
fan start-up "dF" no
longer displayed, cabinet
temperature displayed
Note:
1) Cut-on, cut-off, and cabinet temperature are read by the same sensor, called the
"cabinet thermistor."
2) The defrost thermistor reads the evaporator temperature.
3) There is a ve second evaporator fan startup delay when the compressor and
fan would otherwise start together.
13
b) Timing Chart
r
TIME-TEMPERATURE CONTROL CHART ENERGY SAVING MODE
REFRIGERATORS
Refrigerators – Continuous Operating Mode
)yaleD niarD(
.nim 5
)yaleD naF(
.nim 5
)noitaruD tsorfeD .xaM(
.nim 06 <
)yaleD yalpsiD(
.nim 1
)elbatsujdA - tratS tsorfeD(
sruoh 6
Q6 and Later
Q5 and Earlier
)FFO .niM(
.nim 2
)NO .niM(
.nim 2
)yaleD tratS(
.nim 2
)+( laitnereffiD + tniopteS
gninaem oN
rotsimrehT tsorfeD
erutarepmeT noitanimreT tsorfeD
)--( laitnereffiD + tniopteS
rotsimrehT tenibaC
FFO
NO
osserpmoC
FFO
NO
naF resnednoC
FFO
NO
n(s)aF rotaropavE
retaeH tsorfeD
FFO
NO
rotacidnI tsorfeD
FFO
NO
FFO
NO
Frame Heater(s)
14
emiT
NO rewoP
2. Freezers – Continuous Operating Mode
a) Sequence of Operation
POWER ON
Board Self Check
1. Frame heater(s) on
2. Evaporator fan(s) on
Cycle On (Cut-on
temperature reached)
[Minimum 2 minutes]
1. Compressor start-up
2. Condenser fan start-up
Continue as
normal cycling
2 minute delay
1. Compressor start-up
2. Condenser fan start-up
Defrost Start
Preprogrammed time interval
1. Compressor off
2. Evaporator fan(s) off
3. Condenser fan off
4. Defrost heater on
5. "dF" displayed
Cycle Off (Cut-out
temperature reached)
[Minimum 2 minutes]
1. Compressor off
2. Condenser fan off
Defrost end
Defrost thermistor
reaches defrost
termination
temperature, or defrost
timer reaches 1 hour
Defrost heater off
Five minutes after
defrost heater off
1. Compressor on
2. Condenser fan on
Five minutes after
compressor start-up
1. Evaporator fan(s) on
Eight minutes after evaporator
fan start-up "dF" no longer
displayed, cabinet temperature
displayed
Note:
1) Cut-on, cut-off, and cabinet temperature are read by the same sensor, called the
"cabinet thermistor."
2) The defrost thermistor reads the evaporator temperature.
3) There is a ve second evaporator fan startup delay when the compressor and
fan would otherwise start together.
15
b) Timing Chart
r
r
r
r
r
TIME-TEMPERATURE CONTROL CHART [NOT DURING ENERGY SAVING MODE] FOR
REFRIGERATORS & FREEZERS WITH AUXILIARY CODE _____ AND BEFORE
Freezers – Continuous Operating Mode
)yaleD naF(
.nim 5
)yaleD niarD(
.nim 5
)yaleD yalpsiD(
.nim 8
)noitaruD tsorfeD .xaM(
.nim 06 <
)FFO .niM(
.nim 2
)NO .niM(
.nim 2
)yaleD tratS(
.nim 2
)+( laitnereffiD + tniopteS
erutarepmeT noitanimreT tsorfeD
gninaem oN
otsimrehT tsorfeD
)--( laitnereffiD + tniopteS
otsimrehT tenibaC
FFO
NO
osserpmoC
FFO
NO
naF resnednoC
FFO
NO
n(s)aF rotaropavE
FFO
NO
etaeH tsorfeD
FFO
NO
otacidnI tsorfeD
FFO
NO
)elbatsujdA - tratS tsorfeD(
sruoh 6
emiT
NO rewoP
Frame Heater(s)
16
3. Refrigerators – Energy Saving Operating Mode
a) Sequence of Operation
POWER ON
Board Self Check
1. Frame heater(s) on continuously
(Q5 and earlier)
Frame heater(s) cycle on and off
(Q6 and later)
2. Evaporator fan(s) cycles on and off
Cycle On (Cut-on
temperature reached)
[Minimum 2 minutes]
1. Compressor start-up
2. Condenser fan start-up
3. Frame heater(s) on
(continuously)
4. Evaporator fan(s) on
(continuously)
Continue as
normal cycling
Defrost Start
Preprogrammed time interval
1. Compressor off
2. Frame heater(s) off (Q6 and later)
3. Evaporator fan(s) off
4. Condenser fan off
5. Defrost heater on
6. "dF" displayed
2-minute Delay
1. Compressor start-up
2. Condenser fan start-up
3. Frame heater(s) on
(continuously)
4. Evaporator fan(s) on
(continuously)
Cycle Off (Cut-out
temperature reached)
[Minimum 2 minutes]
1. Compressor off
2. Condenser fan off
3. Frame heater(s)
cycle on and off
(Q6 and later)
4. Evaporator fan(s)
cycles on and off
Defrost End
Defrost thermistor
reaches defrost
termination temperature,
or defrost timer reaches
1 hour
Defrost heater off
Five minutes after
defrost heater off
1. Compressor on
2. Condenser fan on
Five minutes after
compressor start-up
1. Evaporator fan(s) on
2. Frame heater(s)
on (Q6 and later)
One minute after evaporator
fan start-up "dF" no longer
displayed, cabinet temperature
displayed
Note:
1) Cut-on, cut-off, and cabinet temperature are read by the same sensor, called the "cabinet
2) The defrost thermistor reads the evaporator temperature.
thermistor."
17
b) Timing Chart
r
r
TIME-TEMPERATURE CONTROL CHART [DURING ENERGY SAVING MODE] FOR
REFRIGERATORS WITH AUXILIARY CODE _____ AND AFTER
Refrigerators – Energy Saving Operating Mode
)sdoireP FFO rosserpmoC llA(
*
tnettimretnI
noitarepO
)yaleD yalpsiD(
.nim 1
rehtegot trats esiwrehto dluow naf dna rosserpmoc
nehw yaled pu trats naf rotaropave dnoces eviF
*
)yaleD naF(
.nim 5
)yaleD niarD(
.nim 5
)noitaruD tsorfeD .xaM(
.nim 06 <
)elbatsujdA - tratS tsorfeD(
sruoh 6
Q6 and Later
Q5 and Earlier
)sdoireP FFO rosserpmoC llA(
*
tnettimretnI
noitarepO
)FFO .niM(
.nim 2
)NO .niM(
.nim 2
)yaleD tratS(
.nim 2
)--( laitnereffiD + tniopteS
)+( laitnereffiD + tniopteS
gninaem oN
rotsimrehT tsorfeD
erutarepmeT noitanimreT tsorfeD
rotsimrehT tenibaC
FFO
NO
osserpmoC
FFO
NO
naF resnednoC
NO
18
*
FFO
n(s)aF rotaropavE
FFO
NO
etaeH tsorfeD
rotacidnI tsorfeD
FFO
NO
FFO
NO
Frame Heater(s)
emiT
NO rewoP
4. Freezers – Energy Saving Operating Mode
a) Sequence of Operation
POWER ON
Board Self Check
1. Frame heater(s) on
2. Evaporator fan(s)
cycles on and off
Cycle On (Cut-on
temperature reached)
[Minimum 2 minutes]
1. Compressor start-up
2. Condenser fan start-up
3. Evaporator fan(s) on
(continuously)
Continue as
normal cycling
2-minute Delay
1. Compressor start-up
2. Condenser fan start-up
3. Evaporator fan(s) on
(continuously)
Defrost Start
Preprogrammed time interval
1. Compressor off
2. Evaporator fan(s) off
3. Condenser fan off
4. Defrost heater on
5. "dF" displayed
Cycle Off (Cut-out
temperature reached)
[Minimum 2 minutes]
1. Compressor off
2. Condenser fan off
3. Evaporator fan(s)
cycles on and off
Defrost End
Defrost thermistor
reaches defrost
termination temperature,
or defrost timer reaches
1 hour
Defrost heater off
Five minutes after
defrost heater off
1. Compressor on
2. Condenser fan on
Five minutes after
compressor start-up
1. Evaporator fan(s) on
Eight minutes after evaporator
fan start-up "dF" no longer
displayed, cabinet temperature
displayed
Note:
1) Cut-on, cut-off, and cabinet temperature are read by the same sensor, called the "cabinet
2) The defrost thermistor reads the evaporator temperature.
thermistor."
19
b) Timing Chart
)y
TIME-TEMPERATURE CONTROL CHART [DURING ENERGY SAVING MODE] FOR
FREEZERS (ALL UNITS)
Freezers – Energy Saving Operating Mode
*
)sdoireP FFO rosserpmoC llA(
tnettimretnI
noitarepO
)yaleD yalpsiD(
.nim 8
rehtegot trats esiwrehto dluow naf dna rosserpmoc
nehw yaled pu trats naf rotaropave dnoceseviF
*
)yaleD naF(
.nim 5
)yaleD niarD(
.nim 5
)noitaruD tsorfeD .xaM(
)elbatsujdA - tratS tsorfeD(
.nim 06 <
sruoh 6
*
)sdoireP FFO rosserpmoC llA(
tnettimretnI
noitarepO
)FFO .niM(
.nim 2
)NO .niM(
.nim 2
emiT
.nim 2
tratS(
aleD
)+( laitnereffiD + tniopteS
rotsimrehT tsorfeD
erutarepmeT noitanimreT tsorfeD
gninaem oN
)--( laitnereffiD + tniopteS
rotsimrehT tenibaC
rosserpmoC
FFO
NO
FFO
NO
naF resnednoC
NO
*
retaeH tsorfeD
FFO
n(s)aF rotaropavE
FFO
NO
rotacidnI tsorfeD
FFO
NO
FFO
NO
Frame Heater(s)
NO rewoP
20
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