Hoshizaki American, Inc. HPR100A Service Manual
Hoshizaki America, Inc.
Hoshizaki
Commercial Kitchen Equipment
Model
Refrigerated Prep Table with Raised Rail
“A Superior Degree
of Reliability”
www.hoshizaki.com
SERVICE MANUAL
Number: 73168
Issued: 8-12-2009
IMPORTANT
Only qualied service technicians should install, service, and maintain the
unit. 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, component life, and warranty coverage.
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 3069
Attn: Hoshizaki Technical Support Department
Phone: 1-800-33-1940 Technical Support
(770) 487-331
Fax: 1-800-843-1056
(770) 487-3360
E-mail: techsupport@hoshizaki.com
Web Site: www.hoshizaki.com
NOTE: To expedite assistance, all correspondence/communication MUST include the
following information:
• Model Number __________________________
• Serial Number __________________________
• Complete and detailed explanation of the problem.
IMPORTANT
This manual should be read carefully before the unit is serviced or
maintenance operations are performed. Only qualied service technicians
should install, service, and maintain the unit. 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
Important Safety Information ................................................................................................. 6
I. Specications ..................................................................................................................... 7
A. Nameplate Ratings ....................................................................................................... 7
B. Dimensions ................................................................................................................... 7
II. General Information .......................................................................................................... 8
A. Construction .................................................................................................................. 8
B. Sequence of Operation ................................................................................................. 9
1. Startup .................................................................................................................... 9
. Cool Down .............................................................................................................. 9
3. Cool Down Achieved .............................................................................................. 9
4. Cool Down Restart ................................................................................................ 10
5. Cabinet Defrost ..................................................................................................... 10
6. Rail Defrost ............................................................................................................ 11
C. Sequence of Operation Charts ................................................................................... 1
1. Cabinet Cooling ..................................................................................................... 1
. Cabinet and Rail Cooling ....................................................................................... 13
D. Control Board ............................................................................................................. 15
1. Control Board Location .......................................................................................... 15
. Control Board Layout ............................................................................................ 16
3. Features ................................................................................................................ 17
4. Controls and Adjustments ..................................................................................... 18
a) Switch Settings ................................................................................................ 18
b) Temperature Display ....................................................................................... 18
c) Temperature Setpoint ...................................................................................... 19
d) Cabinet Defrost ................................................................................................ 19
e) Energy Saving Mode ....................................................................................... 19
f) Temperature Correction Factor ........................................................................ 0
5. Service Menu ........................................................................................................ 1
a) Service Menu Access ...................................................................................... 1
b) Service Menu Chart .........................................................................................
6. Alarm Signals ...................................................................................................... 3
7. Control Board Check Procedure ........................................................................... 3
8. Control Board Replacement .................................................................................. 3
E. Thermistor Check ....................................................................................................... 4
F. Perimeter Heater ......................................................................................................... 4
G. Compressor Protector ................................................................................................ 4
3
III. Service Diagnosis ........................................................................................................... 5
A. Alarm Signals .............................................................................................................. 5
1. High Temperature Alarm (E1) ............................................................................... 7
. Low Temperature Alarm (E) ................................................................................ 8
3. Cabinet Defrost Alarm (E3) ................................................................................... 9
4. High Condenser Temperature Alarm (clogged lter) (E7) ..................................... 30
5. Defrost Thermistor (cabinet) Malfunction Alarm (E8) ............................................ 31
6. Condenser Thermistor Malfunction Alarm (E9) ..................................................... 3
7. Control Board Alarms (EA and ED) ....................................................................... 33
B. Service Chart .............................................................................................................. 33
1. No Operation ......................................................................................................... 33
. Cabinet Cooling ..................................................................................................... 34
3. Rail Cooling ........................................................................................................... 36
4. Cabinet Defrost .................................................................................................... 37
5. Other ..................................................................................................................... 38
IV. Removal and Replacement of Components .................................................................. 39
A. Service for Refrigerant Lines ...................................................................................... 39
1. Refrigerant Recovery ............................................................................................ 39
. Brazing .................................................................................................................. 40
3. Evacuation and Recharge (R-404A) ..................................................................... 40
B. Removal and Replacement of Refrigeration System Cartridge .................................. 4
1. Refrigerant Recovery Procedure ........................................................................... 4
. Refrigeration System Pump-Down Procedure ..................................................... 44
C. Removal and Replacement of Compressor ................................................................ 47
D. Removal and Replacement of Cabinet Evaporator .................................................... 48
E. Removal and Replacement of Expansion Valve ......................................................... 49
F. Removal and Replacement of Liquid Line Valve ........................................................ 50
G. Removal and Replacement of Condenser.................................................................. 51
H. Removal and Replacement of Thermistors and Thermostat ...................................... 5
1. Cabinet Thermistor ................................................................................................ 5
. Defrost Thermistor ................................................................................................. 5
3. Defrost Thermostat ................................................................................................ 53
4. Rail Thermistor ...................................................................................................... 53
5. Condenser Thermistor (clogged lter) ................................................................... 54
I. Removal and Replacement of Defrost Heater.............................................................. 54
J. Removal and Replacement of Fan Motors .................................................................. 55
1. Cabinet Fan Motor ................................................................................................. 55
. Condenser Fan Motor ........................................................................................... 56
3. Rail Fan Motor ....................................................................................................... 56
K. Removal and Replacement of Door Gasket ............................................................... 57
L. Door Re-Hinging and Drawer Conversion ................................................................... 57
V. Cleaning and Maintenance Instructions .......................................................................... 58
A. Cleaning ...................................................................................................................... 58
1. Work Surface ......................................................................................................... 58
. Rail and Rail Cover ............................................................................................... 59
3. Exterior .................................................................................................................. 59
4. Cabinet Interior ...................................................................................................... 59
4
5. Door/Drawer Gaskets ............................................................................................ 59
6. Shelves (if applicable) ........................................................................................... 59
7. Drawers (if applicable) ........................................................................................... 59
B. Maintenance ............................................................................................................... 60
1. Rail Condensate Pan ............................................................................................ 60
. Air Filter ................................................................................................................. 60
3. Condenser ............................................................................................................. 60
4. Power Supply Connection ..................................................................................... 60
C. Shutdown and Long Storage ...................................................................................... 61
VI. Technical Information .................................................................................................... 6
A. Refrigeration Circuit .................................................................................................... 6
1. HPR46A(-D), HPR7A(-D), HPR100A(-D) ............................................................ 6
B. Wiring Diagrams ......................................................................................................... 63
1. HPR46A(-D) .......................................................................................................... 63
a. HPR7A(-D) Auxiliary Code U-5 and Earlier .......................................................
b. HPR7A(-D) Auxiliary Code U-6 and Later .........................................................
3. HPR100A(-D) ........................................................................................................ 66
64
65
5
Important Safety Information
Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, or damage to the unit.
WARNING Indicates a hazardous situation which could result in death or
serious injury.
CAUTION Indicates a situation which could result in damage to the unit.
IMPORTANT Indicates important information about the use and care of the
unit.
WARNING
This unit 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 eventual damage
caused by improper, incorrect, and unreasonable use.
To reduce the risk of death, electric shock, serious injury, or re, follow
basic precautions including the following:
• This unit requires an independent power supply. See the nameplate for
proper voltage and breaker/fuse size. Failure to use a proper breaker or fuse
can result in a tripped breaker, blown fuse, or damage to existing wiring. This
could lead to heat generation or re.
• THIS APPLIANCE MUST BE GROUNDED: This unit is equipped with a
3-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 -prong outlet, it is your personal responsibility to have a qualied
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.
• Do not use an extension cord.
• Make sure the power switch is in the "OFF" position before plugging in or
unplugging the unit to reduce the risk of electric shock.
• Do not use a unit 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 unit, be sure to pull the
plug, not the cord, and do not jerk the cord.
• To reduce the risk of electric shock, do not touch the plug or power switch
with damp hands.
• This unit should be disassembled or repaired only by qualied service
personnel to reduce the risk of electric shock, injury, or re.
• Do not make any alterations to the unit. Alterations could result in electric
shock, injury, re, or damage to the unit.
6
I. Specications
A. Nameplate Ratings
Design Pressure (PSIG) Refrigerant
Model AC Supply Voltage Amperes
HPR46A(-D)
HPR7A
HPR7A-D
HPR100A(-D) TBD TBD
115/60/1
See Unit Nameplate
7.6
13.6
HI LO 404A
8.5 oz.
450 50
36.1 oz.
B. Dimensions
Model
HPR46A(-D)
(1 Section)
HPR7A(-D)
( Section)
HPR100A(-D)
(3 Section)
Model
HPR46A(-D)
(1 Section)
HPR7A(-D)
( Section)
HPR100A(-D)
(3 Section)
Rail
Interior
Volume
Cu. Ft.
8.5 1
18.8 18 188.8
9.1 6 533.8
Door
Opening
Height
mm (in.)
616.
(4.6)
Capacity
QTY of 1/6
Sized Pans
Opening
Width
(DH)
mm (in.)
(.45)
Door
(DW)
570.3
Exterior
Height
(HE)
mm (in.)
1040
(40.95)
Door
Swing
(DS)
mm (in.)
608.3
(3.95)
Worktop
Height
(HW)
mm (in.)
816
(3.13)
Drawer
Extension
mm (in.)
649.1
(5.56)
Exterior
Width
mm (in.)
1168.4
(99.76)
(DE)
(W)
(46)
(7)
Exterior
Depth
mm (in.)
858.5
(33.79)
Drawer
Gap
(DG)
mm (in.)
19
(0.75)
(D)
Interior
Height
mm (in.)
640.5
(5.)
Door
Open
Position
105°
Interior
Width
mm (in.)
604.1
(3.78)
1309.1
(51.54)
014.1
(79.30)
Rail Cover
Open
Positions
45°
and
65°
Interior
Depth
mm (in.)
641.8
(5.7)
Caster
Height
mm (in.)
101.6
(4)
7
II. General Information
A. Construction
This Hoshizaki unit features a cartridge-type refrigeration system that can be removed
(excluding the rail evaporator).
Rail Cover
Rail Fan Motors and
Fan Shrouds
Compressor
Side Panel
Receiver Tank
Condenser Fan Motor
Cabinet Evaporator
Fan Motors
Cabinet Defrost Thermistor
Refrigeration
Cartridge
Drier
Wire Cover
Front Panel
Air Filter
Control Box
Condenser
Cabinet Evaporator
Assembly
Defrost Thermostat
Cabinet Thermistor
Cabinet Air Duct
Cabinet Interior Side
Panel
8
B. Sequence of Operation
The steps in the sequence are as outlined below.
1. Startup
When the power switch is in the "ON" position, the cabinet temperature is displayed
and cabinet cooling begins. When the power switch is in the "ON" position and the rail
cooling switch is moved to the "NORMAL" or "LOW" position, the rail temperature is
displayed and rail cooling begins. The "NORMAL" rail switch position is designed for use
when the rail cover is open. The "LOW" rail switch position is designed for use when the
rail cover is closed. For further details, see "II.D.4.a) Switch Settings."
a) Power Switch "ON," Rail Cooling Switch "OFF"
Cabinet temperature at or above setpoint: CabFM, CLLV, and PH energize. The
minute Comp delay timer and 6 hour DT start.
b) Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"
Cabinet temperature and rail temperature at or above setpoint: CabFM, CLLV, PH,
RailFM, and RLLV energize. The minute Comp delay timer and 6 hour DT start.
2. Cool Down
a) Power Switch "ON," Rail Cooling Switch "OFF"
CabFM, CLLV, and PH continue. The minute Comp delay timer expires and Comp
and ConFM energize.
b) Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"
CabFM, CLLV, PH, RailFM, and RLLV continue. The minute Comp delay timer
expires and Comp and ConFM energize.
3. Cool Down Achieved
To prevent Comp hard starts, CLLV (rail cooling switch "OFF") or RLLV (rail cooling
switch "NORMAL" or "LOW") remains energized when Comp is off.
a) Power Switch "ON," Rail Cooling Switch "OFF"
CTh reaches 3.6°F (°C) below setpoint. CabFM and PH continue, Comp and ConFM
de-energize. CLLV de-energizes for seconds (CLLV then remains energized during
Comp off time).
b) Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"
CTh, RTh, or both have reached 3.6°F (°C) below setpoint.
(1) Cabinet still cooling, RTh reaches 3.6°F (2°C) below setpoint
CabFM, Comp, CondFM, CLLV, and PH continue. RailFM continues when rail
cooling switch is in the "NORMAL" position and per F9 setting when in the "LOW"
position. For details, see "II.D.4.a) Switch Settings." RLLV de-energizes.
(2) CTh reaches 3.6°F (2°C) below setpoint, rail still cooling
CabFM, Comp, CondFM, PH, RailFM, and RLLV continue. CLLV de-energizes.
9
(3) Both CTh and RTh reach 3.6°F (2°C) below setpoint
CabFM and PH continue. RailFM continues when rail cooling switch is in the
"NORMAL" position and per F9 setting when in the "LOW" position. For details,
see "II.D.4.a) Switch Settings." Comp, ConFM, and CLLV de-energize. RLLV
de-energizes for seconds. RLLV energizes, then remains energized during
Comp off time.
4. Cool Down Restart
a) Power Switch "ON," Rail Cooling Switch "OFF"
CTh warms to setpoint, the CabFM, CLLV, and PH continue. minute Comp delay
timer starts. After the minute delay timer expires, Comp and ConFM energize.
Cycle continues until power is turned off, the 6 hour DT expires and CB initiates
a cabinet defrost, or the "MANUAL DEFROST" button is pressed for 5 seconds
(evaporator temperature must be below 49°F (9.4°C)).
b) Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"
CTh, RTh, or both have warmed to setpoint.
(1) CTh at or above setpoint, RTh warms to setpoint
CabFM, Comp, ConFM, CLLV, PH, continue. RailFM continues when rail switch is
in the "NORMAL" position and resumes continuous operation when in the "LOW"
position. RLLV energizes.
(2) CTh warms to setpoint, RTh at or above setpoint
CabFM, Comp, ConFM, PH, RailFM, and RLLV continue. CLLV energizes.
(3) CTh or RTh warms to setpoint
CabFM, PH, RailFM (RailFM continues when rail switch is in the "NORMAL"
position and resumes continuous operation when in the "LOW" position), and
RLLV continue. The minute Comp delay timer starts. If CTh has warmed to
setpoint and RTh has not, CLLV energizes and RLLV de-energizes. If RTh
has warmed to setpoint and CTh has not, RLLV continues and CLLV remains
de-energized. After the minute Comp delay timer expires, Comp and ConFM
energize.
5. Cabinet Defrost
The rst cabinet defrost occurs 6 hours after the unit is turned on. Cabinet defrost is
initiated when the 6 hour DT expires or the "MANUAL DEFROST" button is pressed
for 5 seconds. Cabinet defrost termination occurs when the evaporator temperature
reaches 49°F (9.4°C). Note that the defrost is a heated defrost, and therefore will have a
tendency to raise the cabinet temperature. Cabinet temperature is not displayed during
defrost; "dF" is displayed in its place. After defrost, there is a 5 minute delay before the
compressor will start.
Note: To prevent Comp hard starts, CLLV (rail cooling switch "OFF") or RLLV (rail
cooling switch "NORMAL" or "LOW") remains energized when Comp is off.
10
a) Cabinet Defrost: Power Switch "ON," Rail Cooling Switch "OFF"
CLLV continues, CabFM, Comp, ConFM, and PH de-energize. DH energizes and
warms DTh to 49°F (9.4°C) (or the 100-minute defrost termination timer expires
or DTst warms to 10°F±5°F (49°C±3°C)). When DTh reaches 49°F (9.4°C),
DH de-energizes, CLLV continues and a 5 minute Comp delay timer starts. When the
5-minute Comp delay timer expires, CabFM and PH energize for 10 seconds. Comp
and ConFM then energize and a 5-minute CabFM and PH delay timer starts. After the
5-minute CabFM and PH delay timer expires, CabFM and PH energize.
b) Cabinet Defrost: Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW"
(1) Cabinet cool down achieved, rail still cooling
Comp, CondFM, RailFM, and RLLV continue. CabFM and PH de-energize, and
CLLV remains de-energized. DH energizes and warms DTh to 49°F (9.4°C) (or
the 100-minute defrost termination timer expires or the DTst warms to 10°F±5°F
(49°C±3°C)). When DTh reaches 49°F (9.4°C), DH de-energizes, Comp, ConFM,
RailFM, and RLLV continue. CabFM and PH energize for 10 seconds. CLLV then
energizes and a 5-minute CabFM and PH delay timer starts. After the 5-minute
CabFM and PH delay timer expires, CabFM and PH energize.
(2) Cabinet still cooling, rail cool down achieved
RailFM continues (RailFM continues when rail switch is in the "NORMAL"
position and per F9 setting when in the "LOW" position), RLLV and DH energize,
CabFM, Comp, ConFM, and PH de-energize. CLLV de-energizes for seconds,
then energizes again. DH warms DTh to 49°F (9.4°C) (or the 100-minute
defrost termination timer expires or the DTst warms to 10°F±5°F (49°C±3°C)).
When DTh reaches 49°F (9.4°C), DH de-energizes, RailFM continues, RLLV
de-energizes, CLLV energizes, and a 5-minute Comp delay timer starts. When the
5-minute Comp delay timer expires, CLLV and RailFM continue. CabFM and PH
energize for 10 seconds. Comp and ConFM then energize and a 5-minute CabFM
and PH delay timer starts. After the 5-minute CabFM and PH delay timer expires,
CabFM and PH energize.
6. Rail Defrost
For rail defrost (manual defrost), remove product from the rail area and store in a
properly refrigerated area, then move the rail cooling switch to the "OFF" position.
Legend: CabFM–cabinet fan motor; CB–control board; Comp–compressor;
ConFM–condenser fan motor; CLLV–cabinet liquid line valve; CTh–cabinet
thermistor; DH–defrost heater; DT–defrost timer; DTh–defrost thermistor;
DTst–defrost thermostat; PH–perimeter heater; RailFM–rail fan motor; RLLV–rail
liquid line valve; RTh–rail thermistor
11
C. Sequence of Operation Charts
1. Cabinet Cooling
From 5 below
DTh in control
4. Cabinet Defrost
CTh reaches
To 5 below
resets
• 6 hour DT expires, then
3.6°F (°C)
termination timer starts
• 100-minute defrost
setpoint
CTh warms to
or more
below setpoint
CLLV energized
CabFM energized
DH energized
CabFM de-energized
Comp de-energized
ConFM de-energized
CLLV energized
PH energized
Comp de-energized
ConFM de-energized
PH de-energized
Legend:
CabFM-cabinet fan motor
Comp-compressor
ConFM-condenser fan motor
CLLV-cabinet liquid line valve
To above
CTh-cabinet thermistor
DH-defrost heater
DT-defrost timer
DTh-defrost thermistor
DTst-defrost thermostat
PH-perimeter heater
CabFM energized
CLLV energized
Comp energized
ConFM energized
PH energized
delay timer starts
-minute Comp
CTh in control
Power Switch "ON," Rail Cooling Switch "OFF"
CabFM energized
CLLV energized
Comp energized
ConFM energized
PH energized
Comp delay
timer starts
1. Startup 2. Cool Down 3. Cool Down Achieved
• -minute
Cycle Steps
• 6-hour DT
starts
CabFM energized
CLLV energized
PH energized
Initial startup
begins here
1
5-minute CabFM and
PH delay timer
Stage 2:
CabFM and PH
energize for 10 sec.
CLLV energized
Comp energized
ConFM energized
5. Cabinet Cool Down Defrost Recovery
(defrost terminated)
DTh reaches 49°F (9.4°C) or
Stage 1:
delay timer
DTst temperature reaches 10°F±5°F (49°C±3°C)
5-minute Comp
From 4
above
CLLV energized
DH de-energized
CabFM de-energized
Comp de-energized
ConFM de-energized
100-minute defrost termination timer expires or
PH de-energized
2. Cabinet and Rail Cooling
From 6
next page
4. Cabinet Defrost
Minimum minute Comp delay
if C and R were off
CTh and/or RTh reaches 3.6°F
(°C) or more below setpoint
3. Cool Down Achieved
To 4
next page
setpoint
warms to
CTh or RTh
C on
C off
C and R off
CabFM energized
PH energized
R off
CabFM energized
CLLV energized
R on
Comp energized
CabFM energized
RailFM energized
RLLV energized
CLLV de-energized
Comp de-energized
Comp energized
ConFM energized
PH energized
RailFM energized
ConFM energized
PH energized
RailFM energized
RLLV energized
ConFM de-energized
Legend:
C-cabinet cooling
RLLV de-energized
CLLV de-energized
CabFM-cabinet fan motor
Comp-compressor
ConFM-condenser fan motor
CLLV-cabinet liquid line valve
CTh-cabinet thermistor
DT-detrost timer
DH-defrost heater
DTh-defrost thermistor
DTst-defrost thermostat
PH-perimeter heater
R-rail cooling
RailFM-rail fan motor
RLLV-rail liquid line valve
RTh-rail thermistor
CTh and RTh in control
C on
R off
CabFM energized
CLLV energized
Comp energized
ConFM energized
PH energized
RailFM energized
RLLV de-energized
• C on-CTh at or above setpoint
• C off-CTh has reached 3.6°F (°C) or more below setpoint
• R on-RTh at or above setpoint
• R off-RTh has reached 3.6°F (°C) or more below setpoint
Comp energized
ConFM energized
PH energized
RailFM energized
RLLV energized
R on
CabFM energized
C off
Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW" Position
When in the "NORMAL" position, RailFM operates continuously.
When in the "LOW" position, RailFM operates continuously when rail is cooling down and intermittently
(per F9 setting) when rail cool down is achieved. See "II.D.4.a) Switch Settings" and "II.D.5. Service Menu."
CLLV de-energized
2. Cool Down
C on
R on
CabFM energized
CLLV energized
Comp energized
ConFM energized
PH energized
RailFM energized
RLLV energized
1. Start
delay timer starts
• 6-hour DT starts
• -minute Comp
CabFM energized
CLLV energized
PH energized
RailFM energized
RLLV energized
Cycle Steps
Initial startup
begins here
13
2. Cabinet and Rail Cooling (continued)
Legend:
C-cabinet cooling
CabFM-cabinet fan motor
Comp-compressor
ConFM-condenser fan motor
CLLV-cabinet liquid line valve
CTh-cabinet thermistor
DH-defrost heater
DT-defrost timer
DTh-defrost thermistor
DTst-defrost thermostat
PH-perimeter heater
To 5 below
R-rail cooling
RailFM-rail fan motor
RLLV-rail liquid line valve
To previous page
CabFM energized
• C on-CTh at or above setpoint
• C off-CTh has reached 3.6°F (°C) or more below setpoint
• R on-RTh at or above setpoint
• R off-RTh has reached 3.6°F (°C) or more below setpoint
C on
PH energized
R off
CabFM and PH
energize for 10 sec.
CLLV energized
RailFM energized
Comp energized
ConFM energized
RLLV de-energized
Stage 2: 5-minute CabFM and
DH energized
RailFM energized
RLLV energized
CabFM de-energized
CLLV de-energized
Comp de-energized
ConFM de-energized
C off
R off
DH energized
RailFM energized
RLLV energized
CabFM de-energized
C on
R off
DTh in control
When in the "NORMAL" position, RailFM operates continuously.
When in the "LOW" position, RailFM operates continuously when rail is cooling down and intermittently
(per F9 setting) when rail cool down is achieved. See "II.D.4.a) Switch Settings" and "II.D.5. Service Menu."
C off
R on
Comp energized
ConFM energized
CLLV de-energized
DH energized
RailFM energized
RLLV energized
PH de-energized
Comp de-energized
ConFM de-energized
PH de-energized
CabFM de-energized
CLLV de-energized
PH de-energized
PH delay timer starts
C on
R on
CabFM and PH
energize for 10 sec.
CLLV energized
Comp energized
Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW" Position (continued)
C on
R off
CLLV energized
RailFM energized
CabFM de-energized
ConFM energized
RailFM energized
RLLV energized
Comp de-energized
ConFM de-energized
DH de-energized
PH de-energized
RLLV de-energized
• 6-hour DT expires, then resets
• 100-minute defrost termination timer starts
4. Cabinet Defrost
C on
R on
Comp energized
ConFM energized
DH energized
RailFM energized
RLLV energized
CabFM de-energized
CLLV de-energized
PH de-energized
5. Cabinet Cool Down Defrost Recovery
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DTh reaches 49°F (9.4°C) or
100-minute defrost termination timer expires or
DTst temperature reaches 10°F± 5°F (49°C±3°C)
Stage 1:
When Comp is off: 5-minute Comp delay timer starts
(defrost terminated)
When Comp is on: 5-minute recovery delay timer starts, Comp continues (rail on)
C on
R on
Comp energized
ConFM energized
RailFM energized
RLLV energized
CabFM de-energized
CLLV de-energized
DH de-energized
PH de-energized
D. Control Board
• A Hoshizaki exclusive solid-state control board is employed in all Hoshizaki
HPR46A(-D), HPR7A(-D), and HPR100A(-D) units.
• All models are pretested and factory set.
CAUTION
1. The control board is fragile; handle very carefully.
. 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 when handling or replacing the control board.
3. Do not touch the electronic devices on the control board or the back of the
control board.
4. Do not attempt to repair the control board.
5. Do not short out power supply to test for voltage.
6. Keep the thermistor leads and pressure switch leads at least 1.5" (38 mm)
away from high voltage leads (100Vac or more) to protect against electrical
noise.
1. Control Board Location
The control panel is located behind the front panel. Follow the instructions and warnings
for safe and efcient operation of the unit.
15
2. Control Board Layout
Display/Change
Rail Setpoint
Rail Temperature,
Alarm Display, and
Service Menu
LED on for
Negative Values
Display/Change
Cabinet Setpoint
Front
"UP" Button
"DOWN" Button
Cabinet Temperature,
Alarm Display, and
Service Menu
Energy Saving Mode LED
(Not used this model)
"SERVICE USE ONLY" Button
"MANUAL DEFROST" button
K341 Connector
# 1, Rail Fan Relay (Orange)
K101 Connector
# 1, 3 Transformer 10V
Control Voltage (Dark Blue)
K151 Connector
# 1, Condenser Thermistor
(Gray) (Clogged Filter
Thermistor)
# 3, 4 Defrost Thermistor (Orange)
(Cabinet) (DTh)
# 5, 6 Cabinet Thermistor (Black) (CTh)
# 7, 8 Service Jumper (White)
K01 Connector
# 1, Rail Switch (Yellow)
# 3, 4 Defrost Thermistor
(Orange. Not used, but must be in
place)
# 5, 6 Rail Thermistor (Black) (RTh)
# 7, 8 Rail Switch (Pink)
Rear
Board Part Number
K311 Connector
# 1, Comp Control
Relay (Brown)
# 3, 4 Cabinet Evaporator
Fan Relay (Red)
# 5, 6 Defrost Heater
Relay (Orange)
Chip Revision
Fuse 3A 15V
K361 Connector
# 1, 3 Rail Liquid Line
Solenoid Valve (RLLV)
# 1, 5 Cabinet Liquid Line
Solenoid Valve (CLLV)
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3. Features
a) LED Display and Service Lock-Out
This control board uses twin LED displays to show system details and diagnostic
information. For control board voltage protection, a 3A 15V fuse is incorporated
into the control board circuitry. A service jumper is also provided to protect against
unwanted changes to the unit's settings. This service lock-out jumper is located on the
K151 connector terminals 7 and 8. See "II.D.4. Controls and Adjustments."
b) Compressor Short Cycle Protection
The start circuit of the compressor is timed such that at power-up and during any
compressor off time, there will be at least a minute delay before the compressor will
start. This protects the compressor against short cycling and potential compressor
damage or failure. To bypass the minute compressor delay timer (for unit
diagnostics), press and hold the rail "SET" button and move the power switch to the
"ON" position.
c) Alarm Signal
Alarm signals (E1 to E9, EA and ED) are designed to protect the unit and food
product. These alarms give information or warnings in the event the unit is operating
out of acceptable parameters. See "III.A. Alarm Signals."
d) Service Menu
A service menu (F0 to F9) allows for viewing and setting of system operating details
and parameters. See "II.D.5. Service Menu."
e) Automatic and Manual Defrost Capabilities
This unit features automatic and manual cabinet defrost capabilities. See "II.D.4.d)
Cabinet Defrost."
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4. Controls and Adjustments
The cabinet and rail temperatures are updated every 30 seconds. The control board is
supplied with a service jumper on the K151 connector. Only the temperature setpoint
and the temperature scale ("F5") may be adjusted with this connector in place. To view
or adjust other selections, see "II.D.5. Service Menu."
a) Switch Settings
Power Switch "OFF": Unit off (both cabinet and rail).
Power Switch "ON": Cabinet temperature is displayed and cabinet cooling begins.
Cabinet fans and perimeter heaters are on and run continuously (except during defrost).
Rail Cooling Switch "OFF": Rail cooling off, cabinet cooling continues.
Rail Cooling Switch "NORMAL: Designed for use when the rail cover is open. Rail
temperature display on and rail cooling begins. The rail fans operate continuously.
Rail Cooling Switch "LOW": Designed for use when the rail cover is closed. Rail
temperature display is on and rail cooling begins. The rail fans operate intermittently
when "F9" is at the factory default setting. For access and adjustments to the "F9"
setting, see "II.D.5. Service Menu."
Note: A Hoshizaki OEM rail cooling switch must be used if replacing the rail cooling
switch. For details see "IV.M. Rail Cooling Switch."
b) Temperature Display
The temperature display can be changed between Fahrenheit and Celsius. To change
the temperature display, press and hold the cabinet "SET" button and the "SERVICE
USE ONLY" button for 5 seconds. "F0" appears in the display screen. Press the up
arrow button until "F5" appears in the display screen. "F5" is the only service menu
selection accessible with the service jumper in place.
Press the cabinet "SET" button to view the temperature display setting. Press the up or
down arrow button to switch between F° and C°. Press the cabinet "SET" button to save
the new setting. Press the cabinet "SET" button and the "SERVICE USE ONLY" button
for 5 seconds to return to normal temperature display.
"SET" buttons used to view current temperature settings.
Cabinet "SET" button used with "SERVICE USE ONLY"
button to enter and exit the service menu.
"MANUAL DEFROST"
button used to initiate
a manual defrost.
"UP" and "DOWN" arrow buttons
used to change temperature
settings, scroll through the service
menu, and to change menu settings.
"SERVICE USE ONLY"
button used with cabinet
"SET" button to enter and
exit the service menu.
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c) Temperature Setpoint
The temperature setpoint is the temperature setting at which the compressor turns on.
The factory default temperature setpoints are 37° (3°C) for the cabinet and 33°F (1°C)
for the rail (see the chart below).
The temperature differential for the compressor to turn off is 3.6°F (°C) below the
temperature setpoint. The temperatures are updated every 30 seconds. If necessary,
adjust the temperature setpoint as outlined below.
Note: The cabinet and rail temperature setpoints must be changed individually.
1) Press the appropriate "SET" button to display the current temperature setpoint.
) Press and hold the appropriate "SET" button while pressing the up or down arrow
button. See the chart below for temperature setpoint ranges.
3) Release the "SET" button. As long as the unit is not turned off, the new setpoint will be
saved automatically after 10 seconds.
Section Temperature Setpoint Range
Cabinet
Rail
1 to 53°F
(-6 to +1°C)
-13 to +53°F
(-5 to +1°C)
Default
37°F
(3°C)
33°F
(1°C)
d) Cabinet Defrost
The automatic cabinet defrost is factory set for once every 6 hours. See "II.D.5. Service
Menu." The cabinet defrost thermistor will signal the control board to start a defrost once
the 6 hour defrost timer has expired and the cabinet evaporator temperature is below
49°F (9.4°C). Defrost is heated, and therefore will have a tendency to raise the cabinet
temperature.
For a manual cabinet defrost press the "MANUAL DEFROST" button on the control
board for 5 seconds to initiate a defrost. This will restart the 6-hour defrost timer.
Cabinet temperature is not displayed during defrost; "dF" is displayed in its place. The
control board will terminate the cabinet defrost and begin defrost recovery when a signal
from the cabinet defrost thermistor is greater than 49°F (9.4°C). After defrost, there is a
5-minute delay before the compressor will start.
This unit has an additional defrost thermistor located behind the wire cover that connects
to the K01 connector, terminals 3 and 4. This thermistor is not used for defrost
purposes on this model, but must be in place for proper operation of the control board.
e) Energy Saving Mode
"Energy Saving Mode" is not used on this unit. The "Energy Saving Mode" LED is
located to the bottom right of the cabinet display and should be off. See "II.D.. Control
Board Layout." If the "Energy Saving Mode" LED is on, press the "SERVICE USE
ONLY" button for 5 seconds to exit and disable the "Energy Saving Mode."
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f) Temperature Correction Factor
In cases where there is a discrepancy between the actual cabinet or rail temperature
and the displayed temperature, a temperature correction factor is used to correct the
displayed temperature.
WARNING
This unit has been factory tested with the default settings listed. Avoid using
this function except to conrm that the setting is correct. If set incorrectly, the
display could show an acceptable temperature even though the temperature
is out of the proper range. This value should only be changed after consulting
with the Hoshizaki Technical Support Department at 1-800-33-1940.
To view the current values, move the power switch to the "ON" position while pressing
the up arrow button. The current cabinet temperature correction factor will be shown. If
"18" is displayed, the value is 1.8°F (1°C). Press the cabinet "SET" button to display the
rail temperature correction factor.
Cabinet
Rail
Temperature Correction Factor
Area Setting Range 1-Section 2-Section 3-Section
-9 to 9°F in 0.9°F increments
(-5 to 5°C in 0.5°C increments)
Negative values are indicated by an LED to the left of the value (Decimals are
not shown on display)
1.8°F (1°C) (0°F (0°C)
0°F (0°C)
Default
TBD
TBD
If it is determined through discussion with Hoshizaki Technical Support that the setting
needs to be changed, follow the steps below.
1) Display the cabinet or rail temperature correction factor as outlined above.
) Press the up or down button to increase or decrease the cabinet value.
3) Press the cabinet "SET" button to save the new cabinet value.
4) Press the cabinet "SET" button again to view the rail value.
5) Press the up or down button to increase or decrease the rail value.
6) Press the cabinet "SET" button to save the new rail value.
7) Turn the power off and then back on. The unit will start running with the new value(s).
[Example]
When the actual cabinet temperature is 5.4°F (3°C) higher than the displayed temperature,
change the temperature correction factor to 5.4°F (3°C), so that the displayed temperature
matches the cabinet temperature.
47.8°F (8.7°C)
5.4°F (3°C)
Difference
°F (6°C)
4.4
Actual Area Temperature
Displayed Temperature
0
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