Hoshizaki HPR46A-D Service Manual

Hoshizaki HPR46A-D Service Manual
Hoshizaki
Hoshizaki America, Inc.
Commercial Kitchen Equipment
Model
Refrigerated Prep Table with Raised Rail
“A Superior Degree
of Reliability”
SERVICE MANUAL
www.hoshizaki.com
Number: 73168
Issued: 8-12-2009
Revised: 5-11-2011
IMPORTANT
Only qualified 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 qualified 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:
• Model Number __________________________
• Serial Number __________________________
• Complete and detailed explanation of the problem.
2
IMPORTANT
This manual should be read carefully before the unit is serviced or
maintenance operations are performed. Only qualified 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. Specifications....................................................................................................................... 7
A. Nameplate Ratings......................................................................................................... 7
B. Dimensions.................................................................................................................... 7
II. General Information ........................................................................................................... 8
A. Construction................................................................................................................... 8
B. Sequence of Operation.................................................................................................. 9
1. Startup ..................................................................................................................... 9
2. 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.................................................................................... 12
1. Cabinet Cooling....................................................................................................... 12
2. Cabinet and Rail Cooling........................................................................................ 13
D. Control Board............................................................................................................... 15
1. Control Board Location........................................................................................... 15
2. 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........................................................................... 20
5. Service Menu......................................................................................................... 21
a) Service Menu Access....................................................................................... 21
b) Service Menu Chart.......................................................................................... 22
6. Alarm Signals ....................................................................................................... 23
7. Control Board Check Procedure.............................................................................. 23
8. Control Board Replacement................................................................................... 23
E. Thermistor Check......................................................................................................... 24
F. Perimeter Heater........................................................................................................... 24
G. Compressor Protector.................................................................................................. 24
3
III. Service Diagnosis............................................................................................................ 25
A. Alarm Signals............................................................................................................... 25
1. High Temperature Alarm (E1).................................................................................. 27
2. Low Temperature Alarm (E2).................................................................................. 28
3. Cabinet Defrost Alarm (E3)..................................................................................... 29
4. High Condenser Temperature Alarm (clogged filter) (E7)....................................... 30
5. Defrost Thermistor (cabinet) Malfunction Alarm (E8)............................................. 31
6. Condenser Thermistor Malfunction Alarm (E9)...................................................... 32
7. Control Board Alarms (EA and ED)......................................................................... 33
B. Service Chart............................................................................................................... 33
1. No Operation........................................................................................................... 33
2. 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
2. Brazing................................................................................................................... 40
3. Evacuation and Recharge (R-404A)....................................................................... 40
B. Removal and Replacement of Refrigeration System Cartridge.................................... 42
1. Refrigerant Recovery Procedure............................................................................. 42
2. 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........................................ 52
1. Cabinet Thermistor.................................................................................................. 52
2. Defrost Thermistor.................................................................................................. 52
3. Defrost Thermostat................................................................................................. 53
4. Rail Thermistor....................................................................................................... 53
5. Condenser Thermistor (clogged filter).................................................................... 54
I. Removal and Replacement of Defrost Heater............................................................... 54
J. Removal and Replacement of Fan Motors.................................................................... 55
1. Cabinet Fan Motor................................................................................................... 55
2. 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
2. 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
2. Air Filter.................................................................................................................. 60
3. Condenser.............................................................................................................. 60
4. Power Supply Connection....................................................................................... 60
C. Shutdown and Long Storage........................................................................................ 61
VI. Technical Information ...................................................................................................... 62
A. Refrigeration Circuit..................................................................................................... 62
1. HPR46A(-D), HPR72A(-D), HPR100A(-D).............................................................. 62
B. Wiring Diagrams........................................................................................................... 63
1. HPR46A(-D)............................................................................................................ 63
2a. HPR72A(-D) Auxiliary Code U-5 and Earlier........................................................ 64
2b. HPR72A(-D) Auxiliary Code U-6 and Later.......................................................... 65
3. HPR100A(-D)......................................................................................................... 66
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 fire, 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 fire.
• 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 2-prong outlet, it is your personal responsibility to have a qualified
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 fire. 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 qualified service
personnel to reduce the risk of electric shock, injury, or fire.
• Do not make any alterations to the unit. Alterations could result in electric
shock, injury, fire, or damage to the unit.
6
I. Specifications
A. Nameplate Ratings
Model
HPR46A(-D)
HPR72A
HPR72A-D
HPR100A(-D)
AC Supply Voltage
Design Pressure (PSIG)
HI
LO
Amperes
7.6
See Unit Nameplate
13.6
TBD
115/60/1
450
Refrigerant
404A
28.5 oz.
250
36.1 oz.
TBD
B. Dimensions
Interior
Volume
Cu. Ft.
Rail
Capacity
QTY of 1/6
Sized Pans
HPR46A(-D)
(1 Section)
8.5
12
HPR72A(-D)
(2 Section)
18.8
18
HPR100A(-D)
(3 Section)
29.1
26
Model
Model
Exterior
Height
(HE)
mm (in.)
Worktop
Height
(HW)
mm (in.)
Exterior
Width
(W)
mm (in.)
Exterior
Depth
(D)
mm (in.)
Interior
Height
mm (in.)
1168.4
(46)
1040
(40.95)
816
(32.13)
1828.8
(72)
2533.8
(99.76)
858.5
(33.79)
Door
Opening
Height
(DH)
mm (in.)
Door
Opening
Width
(DW)
mm (in.)
Door
Swing
(DS)
mm (in.)
Drawer
Extension
(DE)
mm (in.)
Drawer
Gap
(DG)
mm (in.)
616.2
(24.26)
570.3
(22.45)
608.3
(23.95)
649.1
(25.56)
19
(0.75)
HPR100A(-D)
(3 Section)
7
Interior
Depth
mm (in.)
604.1
(23.78)
640.5
(25.22)
1309.1
(51.54)
2014.1
(79.30)
641.8
(25.27)
Door
Open
Position
Rail Cover
Open
Positions
Caster
Height
mm (in.)
105°
45°
and
65°
101.6
(4)
HPR46A(-D)
(1 Section)
HPR72A(-D)
(2 Section)
Interior
Width
mm (in.)
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
Front Panel
Receiver Tank
Air Filter
Drier
Control Box
Condenser Fan Motor
Wire Cover
Condenser
Cabinet Evaporator Cabinet Evaporator
Assembly
Fan Motors
Cabinet Defrost Thermistor
Refrigeration
Cartridge
Defrost Thermostat
Cabinet Thermistor
Cabinet Interior Side
Panel
8
Cabinet Air Duct
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
2 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 2 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 2 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 2 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 (2°C) below setpoint. CabFM and PH continue, Comp and ConFM
de‑energize. CLLV de-energizes for 2 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 (2°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 2 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. 2 minute Comp delay
timer starts. After the 2 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 2 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 2 minute Comp delay timer expires, Comp and ConFM
energize.
5. Cabinet Defrost
The first 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 120°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 120°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 2 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 120°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
12
From 4
above
CLLV energized
DH de-energized
CabFM de-energized
Comp de-energized
ConFM de-energized
PH de-energized
CabFM and PH
energize for 10 sec.
CLLV energized
Comp energized
ConFM energized
• 6 hour DT expires, then
resets
• 100-minute defrost
termination timer starts
To 2 above
CabFM energized
CLLV energized
Comp energized
ConFM energized
PH energized
DTh reaches 49°F (9.4°C) or
100-minute defrost termination timer expires or
DTst temperature reaches 120°F±5°F (49°C±3°C)
Stage 2:
Stage 1:
5-minute CabFM and
5-minute Comp
PH delay timer
delay timer
5. Cabinet Cool Down Defrost Recovery
(defrost terminated)
CabFM energized
CLLV energized
PH energized
Comp de-energized
ConFM de-energized
CTh in control
CTh reaches
3.6°F (2°C)
or more
below setpoint
DTh in control
4. Cabinet Defrost
To 5 below
From 5 below
Legend:
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
CLLV energized
DH energized
CabFM de-energized
Comp de-energized
ConFM de-energized
PH de-energized
3. Cool Down Achieved
2-minute Comp
delay timer starts
2. Cool Down
CabFM energized CabFM energized
CLLV energized CLLV energized
Comp energized
PH energized
ConFM energized
PH energized
Initial startup
begins here
• 2-minute
Comp delay
timer starts
• 6-hour DT
starts
1. Startup
CTh warms to
setpoint
Cycle Steps
Power Switch "ON," Rail Cooling Switch "OFF"
C. Sequence of Operation Charts
1. Cabinet Cooling
CabFM energized
CLLV energized
PH energized
RailFM energized
RLLV energized
Initial startup
begins here
13
CabFM energized
CLLV energized
Comp energized
ConFM energized
PH energized
RailFM energized
RLLV de-energized
CabFM energized
Comp energized
ConFM energized
PH energized
RailFM energized
RLLV energized
CLLV de-energized
CabFM energized
CLLV energized
Comp energized
ConFM energized
PH energized
RailFM energized
RLLV energized
CabFM energized
Comp energized
ConFM energized
PH energized
RailFM energized
RLLV energized
CLLV de-energized
C off
R on
• C on-CTh at or above setpoint
• C off-CTh has reached 3.6°F (2°C) or more below setpoint
• R on-RTh at or above setpoint
• R off-RTh has reached 3.6°F (2°C) or more below setpoint
C on
R off
CabFM energized
PH energized
RailFM energized
RLLV energized
CLLV de-energized
Comp de-energized
ConFM de-energized
CabFM energized
CLLV energized
Comp energized
ConFM energized
PH energized
RailFM energized
RLLV de-energized
Legend:
C-cabinet cooling
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
C and R off
To 4
next page
From 6
next page
4. Cabinet Defrost
C on
R off
Minimum 2 minute Comp delay
if C and R were off
CTh and/or RTh reaches 3.6°F
(2°C) or more below setpoint
3. Cool Down Achieved
CTh and RTh in control
C off
R on
2. Cool Down
C on
R on
• 2-minute Comp
delay timer starts
• 6-hour DT starts
1. Start
CTh or RTh
warms to
setpoint
Cycle Steps
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."
2. Cabinet and Rail Cooling
14
Comp energized
ConFM energized
DH energized
RailFM energized
RLLV energized
CabFM de-energized
CLLV de-energized
PH de-energized
C off
R on
DH energized
RailFM energized
RLLV energized
CabFM de-energized
CLLV de-energized
Comp de-energized
ConFM de-energized
PH de-energized
C off
R off
DH energized
RailFM energized
RLLV energized
CabFM de-energized
CLLV de-energized
Comp de-energized
ConFM de-energized
PH de-energized
C on
R off
Comp energized
ConFM energized
RailFM energized
RLLV energized
CabFM de-energized
CLLV de-energized
DH de-energized
PH de-energized
C on
R on
CLLV energized
RailFM energized
CabFM de-energized
Comp de-energized
ConFM de-energized
DH de-energized
PH de-energized
RLLV de-energized
C on
R off
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
R-rail cooling
RailFM-rail fan motor
RLLV-rail liquid line valve
C on
R off
CabFM and PH
energize for 10 sec.
CLLV energized
RailFM energized
Comp energized
ConFM energized
RLLV de-energized
C on
R on
CabFM and PH
energize for 10 sec.
CLLV energized
Comp energized
ConFM energized
RailFM energized
RLLV energized
CabFM energized
PH energized
To 2 previous page
• C on-CTh at or above setpoint
• C off-CTh has reached 3.6°F (2°C) or more below setpoint
• R on-RTh at or above setpoint
• R off-RTh has reached 3.6°F (2°C) or more below setpoint
To 5 below
DTh reaches 49°F (9.4°C) or
100-minute defrost termination timer expires or
DTst temperature reaches 120°F± 5°F (49°C±3°C)
Stage 1:
Stage 2: 5-minute CabFM and
When Comp is off: 5-minute Comp delay timer starts
When Comp is on: 5-minute recovery delay timer starts, Comp continues (rail on) PH delay timer starts
5. Cabinet Cool Down Defrost Recovery
(defrost terminated)
Comp energized
ConFM energized
DH energized
RailFM energized
RLLV energized
CabFM de-energized
CLLV de-energized
PH de-energized
C on
R on
DTh in control
• 6-hour DT expires, then resets
• 100-minute defrost termination timer starts
4. Cabinet Defrost
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."
Power Switch "ON," Rail Cooling Switch "NORMAL" or "LOW" Position (continued)
2. Cabinet and Rail Cooling (continued)
D. Control Board
• A Hoshizaki exclusive solid-state control board is employed in all Hoshizaki
HPR46A(‑D), HPR72A(-D), and HPR100A(-D) units.
• All models are pretested and factory set.
CAUTION
1. The control board is 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 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 efficient operation of the unit.
15
2. Control Board Layout
Display/Change
Rail Setpoint
Display/Change
Cabinet Setpoint
"UP" Button
"DOWN" Button
Cabinet Temperature,
Alarm Display, and
Service Menu
Rail Temperature,
Alarm Display, and
Service Menu
Energy Saving Mode LED
(Not used this model)
"SERVICE USE ONLY" Button
LED on for
Negative Values
"MANUAL DEFROST" button
Front
Board Part Number
K311 Connector
# 1, 2 Comp Control
Relay (Brown)
# 3, 4 Cabinet Evaporator
Fan Relay (Red)
# 5, 6 Defrost Heater
Relay (Orange)
K341 Connector
# 1, 2 Rail Fan Relay (Orange)
Chip Revision
K101 Connector
# 1, 3 Transformer 10V
Control Voltage (Dark Blue)
Fuse 3A 125V
K151 Connector
# 1, 2 Condenser Thermistor
(Gray) (Clogged Filter
Thermistor)
# 3, 4 Defrost Thermistor (Orange)
(Cabinet) (DTh)
# 5, 6 Cabinet Thermistor (Black) (CTh)
# 7, 8 Service Jumper (White)
K201 Connector
# 1, 2 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
16
K361 Connector
# 1, 3 Rail Liquid Line
Solenoid Valve (RLLV)
# 1, 5 Cabinet Liquid Line
Solenoid Valve (CLLV)
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 125V 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 2 minute delay before the compressor will
start. This protects the compressor against short cycling and potential compressor
damage or failure. To bypass the 2 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." 17
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.
"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.
"MANUAL DEFROST"
button used to initiate
a manual defrost.
18
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 (2°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.
2) 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
21 to 53°F
Cabinet
(-6 to +12°C)
-13 to +53°F
Rail
(-25 to +12°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 K201 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.2. 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."
19
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 confirm 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 1-800-233-1940.
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.
Temperature Correction Factor
Area
Setting Range
Cabinet
-9 to 9°F in 0.9°F increments
Rail
1-Section
Default
2-Section
3-Section
TBD
0°F (0°C)
TBD
(-5 to 5°C in 0.5°C increments)
1.8°F (1°C) (0.9°F (0.5°C)
Negative values are indicated by an LED to the left of the value (Decimals are not
shown on display)
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.
2) 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)
Actual Area Temperature
5.4°F (3°C)
Difference
Displayed Temperature
42.4°F (6°C)
20
5. Service Menu
The service menu ("F0" to "F9") may be used to change settings, acquire diagnostic
information, and to view alarm history.
To access the "F0" through "F9" service menu selections, you must first disconnect the
service jumper (excluding "F5" which is accessible with or without the service jumper in
place). The service jumper is located behind the wire cover below the control box and
connects the control board K151 connector terminals 7 and 8 (white) together. When the
service jumper is in place, only the "F5" selection is accessible. Be sure to reconnect the
service jumper when finished.
a) Service Menu Access
• Enter Service Menu: Press and hold the cabinet "SET" button and the "SERVICE USE
ONLY" button for 5 seconds. "F0" should appear in the display screen.
• Scroll: Use the up and down arrow buttons to scroll through the service menu list,
settings, and data.
• View Service Menu Setting: Press the cabinet "SET" button to view the selected menu
setting.
• Save Setting: Press the cabinet "SET" button to save the new setting.
• Return to Service Menu List: Press the cabinet "SET" button once again to return to the
main service menu list.
• Exit Service Menu: Press and hold the cabinet "SET" button and the "SERVICE
USE ONLY" button for 5 seconds to exit the service menu at any time. If no button is
pressed, the control board will return to the normal temperature display after 1 minute.
"SET" buttons used to view current temperature settings.
Cabinet "SET" button used with "SERVICE USE ONLY"
button to enter and exit the service menu.
"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.
"MANUAL DEFROST"
button used to initiate
a manual defrost.
21
b) Service Menu Chart
Service
Menu Item and Details
F0
Defrost Interval
• The cabinet uses a time initiated
heated defrost.
Setting Range
Cabinet
Rail
1 to 12 hours in
N/A
1 hour increments.
Factory Default
Cabinet
Rail
6
N/A
• The change in the defrost
interval setting will take effect
immediately. The next defrost
will take place after the newly
set time interval has elapsed.
F1
F2
• Initiating a manual defrost on the
cabinet will restart the defrost
timer.
Defrost Termination Temperature
41 to 68°F
N/A
Do not adjust. For
(5 to 20°C)
recommendations, contact
in 1 degree
increments
Hoshizaki Technical Support.
Setpoint Temperature Differential Both the + and - values can be
Use "SET" button to scroll through adjusted between 0 to 6.3°F in
all 4 settings.
increments of .9°F
(0 to 3.5°C in increments of .5°C)
• You cannot set both + and - to
(decimal not displayed)
0.0.
• Negative value indicated by LED
to left of number.
F3
High Temperature Alarm Delay
0 to 3 hours in 1 hour increments
Time: See "III.A. Alarm Signals."
F4
Low Temperature Alarm Delay
0 or 1 hour
Time: See "III.A. Alarm Signals."
F5
Temperature Display
Fahrenheit or Celsius
F6
Alarm History: maximum 8 alarms. Alarms displayed newest to oldest.
When "--" appears, you have
No reset for alarm history
reached the end of the alarm
available.
history.
F7
Compressor Run Time (%):
N/A
Displays compressor run time
percentage between the 2 most
recent defrosts.
F8
Not Used
N/A
F9
Rail Cooling Switch:
0=rail fans on continuously (same
"LOW" Rail Fan Adjustment (rail
as "NORMAL" position)
section only)
1=rail fans on 15 sec.
rail fans off 90 sec.
2=rail fans on 1 sec.
rail fans off 90 sec.
FA
High Condenser Temperature
Adjustable between 140 to 167°F
Do not Alarm Setting (clogged filter):
(60 to 75°C).
adjust For recommendations, contact
Hoshizaki Technical Support.
Fb
Audible Control
N/A
22
49°F (9.4°C)
N/A
Comp on
0°F (0°C)
at setpoint
Comp on
0°F (0°C)
at setpoint
Comp off
Comp off
-3.6°F (-2°C) -3.6°F (-2°C)
below setpoint below setpoint
2
1
°F
N/A
N/A
N/A
N/A
2
140°F (60°C)
(1 not displayed)
N/A
6. Alarm Signals
In the event of operation outside of normal parameters, the control board identifies the
issue with an alarm signal. The alarm signal and temperature are displayed in 1-second
intervals. For service corrections, see "III.A. Alarm Signals."
E1
E2
E3
E4
E7
E8
E9
EA
ED
Alarm Signals
High Temperature Alarm
Low Temperature Alarm
Defrost Alarm (cabinet only)
Not Used
High Condenser Temperature Alarm
(clogged filter)
Defrost Thermistor Malfunction Alarm
Condenser Thermistor Malfunction Alarm
EEPROM Write Error Alarm
EEPROM Verification or Read Error Alarm
7. 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. Before you begin the diagnostics, verify proper supply voltage
and that the unit is correctly plugged in.
1) Move the power switch to the "ON" position and the rail switch to the "NORMAL"
position. Both cabinet and rail temperatures should be displayed. The perimeter heater,
cabinet fans, and rail fans should be on.
2) If the temperature display is not on, check the 3A 125V fuse on the control board and
the control transformer secondary circuit. Secondary transformer output is 10V at
115V primary input. If the fuse and the secondary circuit voltage are good, but the
temperature display is off, the control board is bad and should be replaced.
3) If the temperature display is on and the components are not energizing, verify
12VDC to the corresponding relay. If there is no voltage to the component relay, the
control board is bad and should be replaced.
8. Control Board Replacement
1) Open the front panel. Move the power switch to the "OFF" position, then unplug the
unit.
2) Remove the wire cover, then remove the control box cover.
3) Disconnect the control board wire connectors.
4) Remove the control board.
5) Install the new control board in the control box taking care not to damage it.
6) Connect the control board wire connectors to the new control board.
7) Replace the control box cover in its correct position.
8) Plug in the unit, then move the power switch to the "ON" position to start the unit's
cooling process.
9) Check the setpoint and service menu settings and verify that they are set to the factory
defaults. See "II.D.4. Controls and Adjustments" and "II.D.5. Service Menu."
23
E. Thermistor Check
Thermistors (semiconductors) are used for temperature control in the cabinet and
rail areas, defrost termination, and for monitoring condenser temperature (clogged
filter). The resistance varies depending on temperature. No adjustment is required.
If necessary, check for resistance between thermistor leads and visually check the
thermistor mounting.
1) Disconnect the connector for the thermistor in question under the control box and
behind the wire guard.
2) Remove the thermistor. See "IV.H. Removal and Replacement of Thermistors and
Thermostat."
3) Immerse the thermistor portion in a glass or cup containing ice and water for 2 or
3 minutes.
4) Check for a resistance between thermistor leads. Normal reading is from 5 to 6.5 kΩ
for the cabinet, rail, and defrost thermistors and 145 to 175 kΩ for the condenser
thermistor. Replace the thermistor if it exceeds the normal reading.
F. Perimeter Heater
This unit is equipped with a perimeter heater. This prevents the formation of condensate
on the frame of the unit under high humidity conditions. The unit incorporates a
redundant perimeter heater in the event the main perimeter heater should fail.
G. Compressor Protector
When a combined temperature/amperage value is above the limit specified by the
compressor manufacturer, a protector will operate independently, turning off the
compressor. The compressor will restart when this protector has reset.
Note:
1. Compressor protector resets automatically.
2. If the condenser fan is operating and the compressor is off, it is most likely that the
protector has operated.
24
III. Service Diagnosis
WARNING
1. This unit should be disassembled or repaired only by a qualified service
technician to reduce the risk of injury, electric shock, or fire.
2. Do not make any alterations to the unit. This could cause water leak, electric
shock, or fire.
3. To help reduce the risk of electric shock, do not touch the attachment plug or
switches with damp hands.
4. In case of insufficient refrigeration performance, move the stored food
product into another unit to prevent its deterioration.
A. Alarm Signals
In the event of operation outside of normal parameters, the control board identifies the
issue with an alarm signal. The alarm signal and cabinet temperature are displayed in
1-second intervals. For further service information, see "III.B. Service Chart." If multiple
alarms occur simultaneously, only the alarm with the higher priority is displayed.
Alarm
Priority Problem
Signal
High Temperature Alarm (cabinet only)
E1
8
Cabinet temperature has exceeded the
setpoint temperature by 18°F (10°C) for
more than x hours. The default value of
x is "2".
Low Temperature Alarm (cabinet only)
E2
9
E3
7
Reset, Corrections, and Adjustments
When the temperature returns to the setpoint
range, alarm resets.
Close doors/drawers and clean the condenser and
air filter. Check for refrigerant leaks. Check cabinet
thermistor.
The value of x can be changed under "F3" on the
Service Menu.
(0=No delay; 1=1 hour; 2=2 hours; 3=3 hours)
When the temperature returns to the setpoint
range, alarm resets.
Cabinet temperature has remained
below the setpoint by 9°F (5°C) for more Ambient temperature too low. Check thermistor,
than y hours. The default value of y is
liquid line valve sticking, fans not operating.
"1".
The value of y can be changed under "F4" on the
Service Menu.
(0=No delay; 1=hour)
Turn the power off, then back on.
Defrost Alarm (cabinet only)
Check defrost heater, defrost thermistor.
Cabinet defrost has taken longer than
1 hour. The control board has terminated
defrost.
Note that "E3" may alternate with "dF" instead of
the temperature.
25
Alarm
Priority Problem
Signal
High Condenser Temperature Alarm
(clogged filter)
E7
6
Reset, Corrections, and Adjustments
Turn the power off, then back on.
Condenser temperature is outside of
normal operating temperature. 140°F
(60°C)
Defrost Thermistor Malfunction Alarm
E8
E9
EA
ED
Condenser and/or air filter dirty. Fan motor not
turning. Possible restriction in refrigeration system.
Failure to take action when this alarm activates
could result in damage to the compressor.
After replacing defrost thermistor, alarm resets.
3
4
Defrost thermistor shorted or open.
Condenser Thermistor Malfunction
Alarm
After replacing condenser thermistor, alarm resets.
Condenser thermistor shorted or open.
EEPROM Write Alarm
After replacing control board, alarm resets.
Control board has failed.
EEPROM Verification or Read Alarm
After replacing control board, alarm resets.
2
1
Control board has failed.
26
1. High Temperature Alarm (E1)
If the cabinet or rail temperature exceeds the setpoint temperature by 18°F (10°C) or
more for more than x hours, "E1" is displayed. The default value of x is "2" (2 hours).
The value of x can be changed under "F3" on the service menu. (0=No delay; 1=1; 2=2;
3=3 hours)
Note:
• After the machine has been turned off and then turned back on, the high
temperature alarm feature is not active until the area temperature reaches the
lower setpoint temperature differential.
• The high temperature alarm feature operates even during defrost.
Reset Options
The alarm will automatically reset once the area temperature reaches the lower setpoint
temperature differential.
Possible Causes (for further details, see "III.B. Service Chart")
• Doors or drawers are opened frequently or are not completely closed.
• Trouble with the compressor or a refrigerant leak.
• Trouble with the cabinet or rail thermistor.
• Liquid line valve closed.
Power On
E1 Alarm not Available until
Lower Setpoint is Achieved
E1 Alarm Timer Reset
E1 Alarm Timer
E1 Alarm
over 2 hours
Timer under
2 hours
E1 Alarm
E1 Alarm Temperature 18°F
(10°C) above setpoint temp.
Setpoint Temperature and
Upper Setpoint Differential 0°F (0°C)
Lower Setpoint
Temperature Differential
3.6°F (2°C)
E1 Alarm
Available
Temperature Display
27
E1
Alarm
Reset
E1
Blinking
2. Low Temperature Alarm (E2)
If the cabinet or rail temperature drops below the setpoint temperature by 9°F (5°C) or
more for more than y hours, "E2" is displayed. The default value of y is "1" (1 hour). The
value of y can be changed under "F4" on the service menu. (0=No delay; 1=1 hour)
Note:
• The low temperature alarm timer starts once the cabinet temperature drops 9°F
(5°C) below the setpoint temperature.
• The low temperature alarm feature operates even during defrost.
Reset Options
The alarm will automatically reset once the area temperature reaches the upper setpoint
temperature differential.
Possible Causes (for further details see "III.B. Service Chart")
• Ambient temperature is low.
• Trouble with the cabinet thermistor (black).
• Liquid line valve open.
• Evaporator fans not operating.
Power On
E2 Alarm Reset
Setpoint Temperature and
Upper Setpoint Differential 0°F (0°C)
Lower Setpoint Temperature
Differential -3.6°F (2°C)
E2 Alarm Temperature
9°F (5°C) below setpoint temp.
E2 Alarm
E2 Alarm Timer
under 1 hour
E2 Alarm
Timer over
E2 Alarm
Timer Reset 1 hour
Temperature Display
28
E2
Blinking
3. Cabinet Defrost Alarm (E3)
Once the defrost termination temperature is reached, the signal from the defrost
thermistor should terminate the defrost. If the defrost thermistor does not terminate the
defrost within 100 minutes (1 hour and 40 minutes), "E3" is displayed. When "E3" is
displayed, the next step in the defrost process begins.
Reset Options
To reset the alarm, turn the power off and then back on.
Possible Causes (for further details see "III.B. Service Chart")
• Trouble with the defrost heater.
• Trouble with the defrost thermistor.
• Trouble with the control board.
29
4. High Condenser Temperature Alarm (clogged filter) (E7)
The unit is equipped with a condenser air filter to protect the condenser from dirt, grease,
etc. The condenser air filter promotes clean condenser surfaces and efficient operation
and should be checked twice monthly and cleaned when necessary. The unit is also
equipped with a condenser thermistor to determine if the condenser or condenser air
filter is excessively dirty. If the condenser thermistor detects a temperature that exceeds
the preset temperature value (136.4°F (58°C)) for over 2 minutes, "E7" will be displayed.
CAUTION
Failure to take action when this alarm activates could result in damage to the
compressor.
Reset Options
After cleaning the filter, the alarm will automatically reset once the temperature at the
condenser outlet drops below 136.4°F (58°C).
Possible Causes (for further details see "III.B. Service Chart")
• The condenser or condenser air filter is dirty.
• The condenser fan motor is not functioning.
Note: If the power is turned off and then back on while the alarm signal is displayed,
the alarm may be reset even if the condenser or condenser air filter has not
been cleaned. However, the alarm will repeat once the compressor discharge
temperature reaches 136.4°F (58°C).
E7 Alarm Timer Start
2 min
E7 Alarm
Reset
High
E7 Alarm Temp.
136.4°F (58°C)
E7 Alarm
Low
Temperature Display
E7 Alternating
with Temperature
30
5. Defrost Thermistor (cabinet) Malfunction Alarm (E8)
If the control board detects an open defrost thermistor, "E8" is displayed. When the
control board detects a shorted defrost thermistor, a 10-minute delay timer begins. After
the 10‑minute delay timer expires, "E8" is displayed. To bypass the 10-minute delay
timer, move the power switch to the "OFF" position. Then, while pressing the rail "SET"
button, move the power switch to the "ON" position. • If this alarm appears, first make sure that the thermistor is properly connected to the
control board.
• A shorted defrost thermistor is not detected by the control board during the 1st hour
after power is turned on. To bypass the 1-hour delay timer, move the power switch to
the "OFF" position. Then, while pressing the rail "SET" button, move the power switch
to the "ON" position.
Reset Options
The alarm automatically resets when one of the following conditions is met:
• The defrost thermistor is secured to the control board.
• The defrost thermistor is within normal operating range. For details, see "II.E. Thermistor
Check."
• A functioning defrost thermistor is installed.
Possible Causes
• Trouble with the defrost thermistor. For checkout procedure, see "II.E. Thermistor Check."
• Trouble with the control board reading the defrost thermistor.
E8 Alarm
Timer Start
E8 Alarm Timer Start
Under 10 min.
10 min.
E8 Alarm (short circuit) Reset
E8 (short circuit )
Detection Point
122°F (50°C)
E8
Alarm
E8 Alarm
(open circuit)
Reset
E8 Alarm (open circuit)
Detection Point
-67°F (-55°C)
E8
Alarm
Temperature Display
Temperature
Display
E8
Blinking
E8
Blinking
5a. Secondary Defrost Thermistor (Rail, not used)
The secondary defrost thermistor (located behind the wire cover) is not used for
operation of the unit. It is used for control board programming and should not be
removed. An "E8" alarm occurs when the secondary defrost thermistor is removed or
fails. For details, see "III.A.6. Defrost Thermistor (cabinet) Malfunction Alarm (E8)."
31
6. Condenser Thermistor Malfunction Alarm (E9)
If the control board detects an open condenser thermistor, "E9" is displayed. When the
control board detects a shorted condenser thermistor, a 10-minute delay timer begins.
After the 10‑minute delay timer expires, "E9" is displayed. To bypass the 10-minute
delay timer, move the power switch to the "OFF" position. Then, while pressing the rail
"SET" button, move the power switch to the "ON" position. • If this alarm appears, first make sure that the thermistor is properly connected to the
control board.
• A shorted condenser thermistor is not detected by the control board during the 1st hour
after power is turned on. To bypass the 1-hour delay timer, move the power switch to
the "OFF" position. Then, while pressing the rail "SET" button, move the power switch
to the "ON" position.
Reset Options
The "E9" alarm automatically resets when one of the following conditions is met:
• The condenser thermistor is secured to the control board.
• The condenser thermistor is within normal operating range. For details, see "II.
E. Thermistor Check."
• A functioning condenser thermistor is installed.
Possible Causes
• Trouble with the condenser thermistor. For checkout procedure, see "II.E. Thermistor
Check."
• Trouble with the control board reading the condenser thermistor.
E9 Alarm
Timer Start
E9 Alarm
Timer Start
10 min.
Under 10 min.
E9 Alarm (short circuit) Reset
E9 Alarm (short circuit)
Detection Point
186.8°F (86°C)
E9 Alarm
E9 Alarm (open circuit) Reset
E9 Alarm (open circuit)
Detection Point
-7.6°F (-22°C)
Temperature Display
E9
Alarm
Temperature
E9 Display
E9
Blinking
Blinking
32
7. Control Board Alarms (EA and ED)
"EA" is displayed when an EEPROM write error is detected. "ED" is displayed when an
EEPROM verification or read error is detected.
Reset Options
Replacing the control board with a functioning control board will eliminate this alarm
condition.
B. Service Chart
1. No Operation
Problem
[1] The unit will not
start.
Possible Cause
a) Power Supply
b) Cord and Plug
c) Control Switch
d) Transformer
[2] Cabinet, rail, or
condenser fan will
not start.
1. Open coil winding.
e) Wiring to Control Board 1. Loose connections or
open.
f) Control Board
1. In alarm.
2. Defective.
a) Fan Motor
1. Motor winding open.
2. Bearing worn out.
3. Wiring to fan motor.
b) Evaporator Fan, Rail
Fan, or Compressor
Relay
[3] Compressor will
not start or stops
operating.
1. Unplugged, off,
blown fuse, or tripped
or defective circuit
breaker.
2. Loose connection.
3. Not within
specifications.
1. Defective.
1. "OFF" position.
2. Bad contacts.
c) Control Board
a) Compressor Relay
b) Compressor Control
Relay
c) Start Relay
d) Start Capacitor
e) Wiring to Compressor
4. Fan blade bound.
1. Bad contacts.
2. Coil winding open.
1. Defective.
1. Bad contacts.
1. Bad contacts.
2. Open winding.
1. Bad contacts.
2. Coil winding open.
1. Defective.
1. Loose connection(s).
2. Faulty.
33
Remedy
1. Turn on, replace, or check
and reset. Call electrician if
breaker trips repeatedly.
2. Tighten.
3. Refer to nameplate and
correct.
1. Replace.
1. Move to "ON" position.
2. Check for continuity and
replace.
1. Check continuity and
replace.
1. Check for continuity and
replace.
1. See "III.A. Alarm Signals."
2. Replace.
1. Replace.
2 Replace.
3. Check for loose or open
connection, and replace.
4. Check and replace.
1. Check for continuity and
replace.
2. Replace.
1. Replace.
1. Check for continuity and
replace.
1. Check for continuity and
replace.
2. Replace.
1. Replace.
2. Replace.
1. Check and replace.
1. Tighten.
2. Check continuity and
replace.
Problem
[3] Compressor will
not start or
stops operating.
(continued)
Possible Cause
f) Voltage
g) High Pressure Switch
g) High Pressure Switch
(continued)
h) Thermistors (cabinet
and rail)
i) Compressor Overload
j) Compressor
k) Control Board
1. Too low.
2. Too high.
1. Restricted air flow to
condenser.
2. Condenser air filter
and/or condenser
clogged.
3. Bad contacts.
Remedy
1. Call electrician.
2. Call electrician.
1. Move unit or increase
ventilation.
2. Clean.
3. Check continuity and
replace.
4. Condenser fan motor. 4. See [2] a) and b).
5. Refrigerant line or
5. Recover, remove
component plugged or
restriction, replace drier,
restricted.
evacuate, and recharge.
6. Refrigerant overcharge. 6. Recover, evacuate, and
recharge.
7. Non-condensibles in
7. Recover, replace drier,
system.
evacuate, and recharge.
1. Defective.
1. See "II.E. Thermistor
Check."
1. Defective. (open
1. Replace.
contacts)
1. Open windings.
1. Check for continuity and
replace.
2. Locked rotor.
2. Replace.
1. In alarm or defective.
1. See "III.A. Alarm Signals"
or replace
2. Cabinet Cooling
Problem
[1] Cabinet
temperature too
high.
Possible Cause
a) Warm Food
b) Doors/Drawers
c) Outside Heat Source
d) Air Flow
e) Cabinet Thermistor
f) Setpoint and/or
Temperature
Correction Factor
Remedy
1. Warm food recently
1. Pre-cool food or allow time
placed in cabinet area. for unit to return to setpoint
temperature.
1. Left open, opened too 1. Close.
often.
2. Not sealing, opened
2. Check for sealing, check for
frequently, or open for
door open at time of warm
long intervals.
cabinet temperature.
1. Too close to unit.
1. Separate unit from heat
source.
1. Blockage inside
1. Remove blockage by
cabinet.
removing or redistributing
food product.
1. Defective.
1. See "II.E. Thermistor
Check."
1. Incorrect.
1. Correct setting(s).
See "II.D.4.c) Temperature
Setpoint" or  
"II.D.4.f) Temperature
Correction Factor" for
defaults.
34
Problem
[1] Cabinet
temperature too
high. (continued)
Possible Cause
g) Defrost
Remedy
1. See "4. Cabinet Defrost."
h)
i)
j)
2. See "4. Cabinet Defrost."
1. Clean.
1. Check and replace.
1. Check and replace.
k)
l)
1. Defrost time
insufficient to remove
frost. Operation in
humid conditions.
2. Incomplete defrost.
Air Filter or Condenser 1. Clogged, dirty.
Cabinet Fan Motor
1. Defective.
Cabinet Liquid Line
1. Does not open.
Valve
Service Valve(s)
1. Partially or completely
closed.
Refrigerant
1. Leak.
m) Expansion Valve
n) Compressor
1. Operating erratically.
1. Defective.
o) Control Board
[2] Cabinet temperature a) Setpoint and/or
too low.
Temperature
Correction Factor
1. Defective.
1. Incorrect.
b) Frozen Food
1. Frozen food recently
placed in refrigerator.
1. Defective.
1. Does not close.
c) Cabinet Thermistor
d) Cabinet Liquid Line
Valve
e) Compressor Relay
1. Defective; contacts
welded.
1. In alarm or defective.
f) Control Board
35
1. Confirm service valve is
open.
1. Recover, repair leak,
replace drier, evacuate, and
recharge.
1. Check and replace.
1. See "1.[3] Compressor will
not start or stops operating."
1. Replace.
1. Correct setting(s).
See "II.D.4.c) Temperature
Setpoint" or  
"II.D.4.f) Temperature
Correction Factor" for
defaults.
1. Allow time for unit to return
to setpoint temperature.
1. Check and replace.
1. Check and replace.
1. Replace.
1. See "III.A Alarm Signals" or
replace.
3. Rail Cooling
Problem
Possible Cause
[1] Rail temperature too a) Warm Food
high.
Remedy
1. Pre-cool food or allow time
for unit to return to setpoint
temperature.
b) Rail Pans/Dividers
1. Missing, not in place. 1. Replace. Pans must cover
entire rail for proper cooling.
c) Outside Heat Source
1. Too close to unit.
1. Separate unit from heat
source.
d) Rail Switch
1. "OFF" position.
1. Move to "NORMAL" or
"LOW" position.
2. Bad contacts.
2. Check for continuity and
replace.
e) Rail Thermistor
1. Defective.
1. See "II.E. Thermistor
Check."
f) Setpoint and/or
1. Incorrect.
1. Correct setting(s).
Temperature
See "II.D.4.c) Temperature
Correction Factor
Setpoint" or  
"II.D.4.f) Temperature
Correction Factor" for
defaults.
g) Air Filter or Condenser 1. Clogged, dirty.
1. Clean.
h) Rail Liquid Line Valve 1. Does not open.
1. Check and replace.
i) Service Valve(s)
1. Partially or completely 1. Confirm service valve is
closed.
open.
j) Refrigerant
1. Leak.
1. Recover, repair leak,
replace drier, evacuate, and
recharge.
k) Expansion Valve
1. Operating erratically. 1. Check and replace.
l) Compressor
1. Defective.
1. See "1.[3] Compressor will
not start or stops operating."
m)Control Board
1. Defective.
1. Replace.
[2] Rail temperature too a) Setpoint and/or
1. Incorrect.
1. Correct setting(s).
low.
Temperature
See "II.D.4.c) Temperature
Correction Factor
Setpoint" or  
"II.D.4.f)Temperature
Correction Factor" for
defaults.
b) Frozen Food
1. Frozen food recently 1. Allow time for unit to return
placed in refrigerator.
to setpoint temperature.
c) Rail Thermistor
1. Defective.
1. Check and replace.
d) Rail Liquid Line Valve 1. Does not close.
1. Check and replace.
e) Rail Fan Motor
1. Defective.
1. Check and replace.
f) Control Board
1. Defective.
1. Replace.
1. Warm food recently
placed in rail area.
36
4. Cabinet Defrost
Problem
[1] Cabinet fan motors
on.
[2] Evaporator does
not defrost
completely.
Possible Cause
a) Cabinet Fan Relay
b) Control Board
a) Defrost Thermistor
b) Defrost
c) Defrost Heater
d) Defrost Thermostat
[3] Defrost cycle too
long. (E3 Defrost
Alarm)
e) Cabinet Liquid Line
Valve
a) Defrost
b) Defrost Thermistor
c) Defrost Heater
d) Defrost Thermostat
e) Control Board
Remedy
1. Bad contacts (closed). 1. Check for continuity and
replace.
1. Defective.
1. Replace.
1. Defective.
1. See "II.E. Thermistor
Check."
1. Not enough defrosts 1. Factory default is once
occurring per day.
every 6 hours. See "II.D.5.
Operation in humid
Service Menu."
conditions.
1. Defective.
1. Replace heater.
1. Defective, turning off 1. Replace defrost thermostat.
heaters prematurely,
or fused open.
1. Does not close.
1. Check and replace.
1. Not enough defrosts
occurring per day.
Operation in humid
conditions.
1. Defective.
1. Defective.
1. Defective, turning off
heaters prematurely,
or fused open.
1. Defective.
37
1. Factory default is once
every 6 hours. See "II.D.5
Service Menu."
1. Replace.
1. Replace heater.
1. Replace defrost thermostat.
1. Replace.
5. Other
Problem
[1] Condensate
water overflow.
Possible Cause
a) Cabinet Contents
b) Location of Unit
c) Seals
d) Environment
e) Rail Condensate Pan
[2] Abnormal Noise
a) Fasteners
b) Compressor
c) Fan
d) Relay
e) Liquid Line Valve
Solenoid
1. Loading large volumes
of warm, moist,
uncovered product.
1. Unit located near high
humidity source such
as fryer, steamer, etc.
1. Poor sealing around
evaporator, door/
drawer gaskets.
1. Extreme environment
and door-opening
conditions.
1. Overflowing.
Remedy
1. Pre-cool food. Cover
product with plastic wrap.
1. Relocate.
1. Adjust or replace.
1. Adjust conditions.
1. Empty and clean rail
condensate pan.
1. Loose fasteners allow 1. Tighten fasteners.
vibration of part.
1. Problem with mount. 1. Properly mount
compressor. Replace any
missing grommets.
2. Floodback to
2. Check for signs of
compressor.
floodback to compressor.
Recover, evacuate, and
recharge if necessary.
3. Defective.
3. Replace.
1. Fan blade loose.
1. Adjust and tighten.
2. Defective motor.
2. Replace.
1. Chattering.
1. Replace.
1. Loose.
1. Tighten.
38
IV. Removal and Replacement of Components
WARNING
1. This unit should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
2. Move the power switch to the "OFF" position and unplug the unit before
servicing.
3. Make sure all food zones are clean after the unit is serviced. For cleaning
procedures, see "V. Cleaning and Maintenance Instructions."
A. Service for Refrigerant Lines
WARNING
1. Repairs requiring the refrigeration circuit to be opened must be performed by
properly trained and EPA-certified service personnel.
2. Always recover the refrigerant and store it in an approved container. Do not
discharge the refrigerant into the atmosphere.
3. Use an electronic leak detector or soap bubbles to check for leaks. Add a
trace of refrigerant to the system (if using an electronic leak detector), and
then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A
as a mixture with pressurized air for leak testing.
CAUTION
1. The Polyol Ester (POE) oils used in R-404A units can absorb moisture
quickly. Therefore it is important to prevent moisture from entering the
system when replacing or servicing parts.
2. Always install a new drier every time the sealed refrigeration system is
opened.
3. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
4. When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
5. Do not leave the system open for longer than 15 minutes when replacing or
servicing parts.
1. Refrigerant Recovery
The unit is provided with a receiver service valve, and compressor and rail access
valves. Using proper refrigerant practices, recover the refrigerant from the receiver
service valve and compressor access valve and store it in an approved container. Do not
discharge the refrigerant into the atmosphere.
Note: Attach the high-side gauge manifold hose to the receiver service valve before
opening the receiver service valve.
39
2. Brazing
WARNING
1. R-404A itself is not flammable at atmospheric pressure and temperatures up
to 176°F (80°C).
2. R-404A itself is not explosive or poisonous. However, when exposed to high
temperatures (open flames), these refrigerants can be decomposed to form
hydrofluoric acid and carbonyl fluoride both of which are hazardous.
3. Do not use silver alloy or copper alloy containing arsenic.
4. Use an electronic leak detector or soap bubbles to check for leaks. Add a
trace of refrigerant to the system (if using an electronic leak detector), and
then raise the pressure using nitrogen gas (140 PSIG). DO NOT use R-404A
as a mixture with pressurized air for leak testing.
1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
Note: Because the pipes in the evaporator case are specially coated to resist corrosion,
it is important to make connections outside the evaporator case when possible. If
it is necessary to braze inside the evaporator case, use sandpaper to remove the
coating from the brazing connections before unbrazing the components.
CAUTION
1. Always install a new drier every time the sealed refrigeration system is
opened.
2. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
3. When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
2) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with
pressurized air for leak testing.
3. Evacuation and Recharge (R-404A)
1) Attach a vacuum pump to the system. Be sure to connect the gauge manifold hoses to
the receiver service valve (high-side) and the compressor access valve (low-side). For
high-side system access, run in the receiver service valve stem a couple of turns.
IMPORTANT
The vacuum pump may be the same as those for current refrigerants.
However, the rubber hose and gauge manifold to be used for evacuation and
refrigerant charge should be exclusively for POE oils.
2) Turn on the vacuum pump. Open the gauge manifold valves. Never allow the oil in the
vacuum pump to flow backwards.
40
3) Allow the vacuum pump to pull down to a 29.9" Hg vacuum. Evacuating period depends
on pump capacity.
4) Close both gauge manifold valves.
5) Turn off the vacuum pump. Disconnect the vacuum pump hose and attach it to a
refrigerant service cylinder. Remember to loosen the connection, and purge the air
from the hose. See the nameplate for the required refrigerant charge. Hoshizaki
recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard
No. 700 (latest edition) be used.
6) A liquid charge is recommended for charging an R-404A system. Invert the service
cylinder and place it on scales.
7) Open the high-side gauge manifold valve and allow the system to charge with liquid
until the proper charge is met.
8) If necessary, add any remaining charge to the system through the compressor access
valve. Use a throttling valve or liquid dispensing device to add the remaining liquid
charge through the compressor access valve with the unit running.
9) Back out the receiver service valve stem all the way and tighten. Disconnect the gauge
manifold hoses.
Note: Be sure the receiver service valve stem is backseated all the way out and tight
before disconnecting the gauge manifold hose.
10) Cap the valves to prevent possible leaks.
Upper Attachment Nut
and Washer
Power Switch
Power Cord
Rail Liquid Line Valve
Rail Cooling Switch
Lower Attachment Nut
and Washer
Wire Cover
Receiver Service Valve
Condenser
Compressor
Receiver Tank
Drier
Rail Expansion Valve
Hex Head Bolt
Cabinet Liquid Line Valve
Rail Low-Side
Access Valve
Cabinet Expansion Valve
Rail Low-Side Service Valve
Rail High-Side
Access Valve
Rail Service Valve Bracket
Compressor
Access Valve
Rail High-Side Service Valve
Rail Refrigerant Tubes
Fig. 1
41
B. Removal and Replacement of Refrigeration System Cartridge
CAUTION
The refrigeration system cartridge should not be removed until the refrigerant
has been properly recovered or the refrigeration system has been properly
pumped down. For refrigeration system repairs, the refrigerant recovery
procedure must be used. See "IV.B.1. Refrigerant Recovery Procedure." For
non‑refrigeration system repairs, see "IV.B.2. Pump‑Down Procedure." Do not
discharge the refrigerant into the atmosphere.
1. Refrigerant Recovery Procedure
1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the
unit.
2) Remove the left side panel.
3) Connect the gauge manifold hoses to the receiver service valve (high-side) and the
compressor access valve (low-side). See Fig. 1.
4) Run in the receiver service valve stem a couple of turns for high-side system access.
Note: Be sure the high-side gauge manifold hose is on the receiver service valve
before opening the receiver service valve.
5) Using proper refrigerant practices, recover the refrigerant and store it in an approved
container. Do not discharge the refrigerant into the atmosphere.
6) When the recovery is finished, close the gauge manifold valves and back out the
receiver service valve stem all the way and tighten.
Note: Be sure the receiver service valve stem is backseated all the way out and tight.
7) Close the rail high and low-side service valves. Run in the rail service valve stems all
the way until tight.
Note: Be sure the rail high and low-side service valve stems are seated all the way in
and tight.
8) Disconnect the rail refrigerant tubes from the rail service valves. Use a backup wrench
when loosening the fittings. See Fig. 1.
9) Remove the screw securing the rail service valve bracket.
10) Disconnect the power supply cord connector, rail thermistor connector, and the
perimeter heater/rail fan motor connector.
11) Remove the wire cover below the control box.
12) Remove the upper and lower attachment nuts and washers from the control box and
the hex head bolt from the base of the refrigeration cartridge. See Fig. 1.
42
13) Slide the refrigeration cartridge forward. Support the evaporator as it clears the
evaporator case. See Fig. 2.
CAUTION
1. Be careful when handling the cabinet evaporator assembly. This assembly
includes a defrost heater sheathed in a glass tube. This sheathing can be
easily damaged and may also cause cuts if broken. The defrost heater will
also be hot after a defrost. Use gloves when handling and avoid touching the
glass directly. Also prevent the defrost heater from touching other parts.
2. To avoid refrigerant leaks, be sure to prevent the refrigeration piping from
coming into contact with the frame when removing and replacing the
refrigeration cartridge.
14) Once the repair is made, replace the refrigeration cartridge back into its correct
position. Support the cabinet evaporator as it enters the cabinet evaporator case.
15) Reconnect the rail refrigerant tubes. Use a backup wrench and tighten the fittings 1/6
turn beyond fully seated. Be sure to use a backup wrench when tightening the fittings.
16) Secure the rail service valve bracket back in its correct position.
17) Secure the refrigeration cartridge with the attachment nuts, washers, and the hex head
bolt.
18) Replace the wire cover and panels in their correct positions.
19) Open the rail high and low-side service valves. Back out the rail service valve stems all
the way to their original position and tighten.
Note: Be sure the rail high and low-side service valve stems are backseated all the way
out and tight.
20) Run in the receiver service valve stem a couple of turns for high-side system access.
Note: Be sure the high-side gauge manifold hose is on the receiver service valve
before opening the receiver service valve.
21) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with
pressurized air for leak testing.
22) Evacuate the system. Then, charge the system with refrigerant; see the nameplate for
the required refrigerant charge.
23) Back out the receiver service valve stem all the way and tighten, then close both gauge
manifold valves.
Note: Be sure the receiver service valve stem is backseated all the way out and tight.
24) Cap the valves to prevent a possible leak.
25) Reconnect the power supply cord connector, rail thermistor connector, and perimeter
heater/rail fan motor connector.
26) Plug the unit back in, then move the power switch to the "ON" position to start the unit's
cooling process.
43
2. Refrigeration System Pump‑Down Procedure
1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the
unit.
2) Remove the left side panel.
3) Connect the gauge manifold hoses to the receiver service valve (high-side) and the rail
low-side access valve. See Fig. 1.
Note: Be sure the high-side gauge manifold hose is on the receiver service valve
before opening the receiver service valve.
4) Run in the receiver service valve stem all the way until tight.
Note: Be sure the receiver service valve stem is seated all the way in and tight.
5) Plug the unit back in, then move the power switch to the "ON" position.
6) Move the rail switch to the "NORMAL" position. There is a 2-minute delay before the
compressor starts. Once the compressor starts, the system pump-down begins.
7) When the low-side gauge indicates a vacuum, close the high and low‑side rail service
valves completely. Run in the rail service valve stems all the way until tight.
Note: Be sure the rail high and low-side service valve stems are seated all the way in
and tight.
8) Move the power switch to the "OFF" position, then unplug the unit.
9) Back out the receiver service valve stem all the way until fully seated. Remove the
high‑side gauge manifold hose.
Note: Be sure the receiver service valve stem is backseated all the way out and tight.
10) Use a backup wrench and disconnect the rail refrigerant tubes from the rail high and
low-side service valves. Use a backup wrench when loosening the fittings. See Fig. 1.
11) Remove the screw securing the rail service valve bracket.
12) Disconnect the power supply cord connector, rail thermistor connector, and perimeter
heater/rail fan connector.
13) Remove the wire cover below the control box.
14) Remove the upper and lower attachment nuts and washers from the control box and
the hex head bolt from the base of the refrigeration system cartridge. See Fig. 1.
15) Slide the refrigeration cartridge forward. Support the evaporator as it clears the
evaporator case. See Fig. 2.
CAUTION
1. Be careful when handling the cabinet evaporator assembly. This assembly
includes a defrost heater sheathed in a glass tube. This sheathing can be
easily damaged and may also cause cuts if broken. The defrost heater will
also be hot after a defrost. Use gloves when handling and avoid touching the
glass directly. Also prevent the defrost heater from touching other parts.
2. To avoid refrigerant leaks, be sure to prevent the refrigeration piping from
coming into contact with the frame when removing and replacing the
refrigeration cartridge.
44
16) Once the repair is made, replace the refrigeration cartridge back into its correct
position. Support the cabinet evaporator as it enters the cabinet evaporator case.
17) Reconnect the rail side refrigerant tubes. Use a backup wrench and tighten the fittings
1/6 turn beyond fully seated. Use a backup wrench when tightening the fittings.
18) Secure the rail service valve bracket back in its correct position.
19) Secure the refrigeration cartridge with the attachment nuts, washers, and the hex head
bolt.
20) Replace the wire cover and panels in their correct positions.
21) Connect the high-side gauge manifold hose to the rail high-side access valve.
22) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with
pressurized air for leak testing
23) Evacuate the rail system. Close the gauge manifold valves.
24) Open the rail high and low-side service valves. Back out the rail high and low-side
service valve stems all the way until fully seated.
Note: Be sure the rail high and low-side service valve stems are backseated all the way
out and tight.
25) Remove the gauge manifold hoses.
26) Cap the valves to prevent possible refrigerant leaks.
27) Use an electronic leak detector or soap bubbles to check the rail refrigerant
connections for refrigerant leaks.
28) Reconnect the power supply cord connector, rail thermistor connector, and the
perimeter heater/rail fan connector.
29) Plug the unit back in, then move the power switch to the "ON" position to start the unit's
cooling process.
45
46
Defrost Thermostat
Refrigeration Cartridge
Rail Thermistor
Cabinet Thermistor
Defrost Heater
Evaporator Case
Fan Motor Shroud
Cabinet Evaporator
Cabinet Fan Motors
Defrost Thermistor
Fig. 2
C. Removal and Replacement of Compressor
CAUTION
1. Always install a new drier every time the sealed refrigeration system is
opened.
2. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
3. When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
4. Recover the refrigerant when replacing the compressor. Do not discharge
the refrigerant into the atmosphere.
5. The compressor may be replaced without removing the refrigeration
cartridge. If removing the refrigeration cartridge, see "IV.B. Removal and
Replacement of Refrigeration Cartridge."
Note: When replacing a compressor with a defective winding, be sure to install a new
start capacitor, overload and start relay. Due to the ability of the POE oil in the
compressor to absorb moisture quickly, the compressor must not be opened
more than 15 minutes for replacement or service. Do not mix lubricants of
different compressors even if both are charged with the same type of refrigerant,
except when they use the same lubricant.
1) Move the power switch to the "OFF" position, then unplug the unit.
2) Remove the front, left side, and rear panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the terminal cover on the compressor and disconnect the compressor wiring.
5) Remove the discharge, process, and suction pipes.
6) Remove the hold-down bolts, washers, rubber grommets, and sleeves.
7) Remove the compressor. Unpack the new compressor. Attach the rubber grommets
and sleeves of the prior compressor.
8) Place the new compressor in position, and secure it using the bolts and washers.
9) Remove the drier, then place the new drier in position.
10) Remove the plugs from the suction, discharge, and process pipes.
11) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
12) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with
pressurized air for leak testing.
13) Evacuate the system, and charge it with refrigerant; see the nameplate for the required
refrigerant charge.
14) Connect the compressor terminals, then replace the terminal cover in its correct
position.
47
15) Replace the panels in their correct positions.
16) Plug in the unit, then move the power switch to the "ON" position to start the unit's
cooling process.
D. Removal and Replacement of Cabinet Evaporator
CAUTION
1. Always install a new drier every time the sealed refrigeration system is
opened.
2. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
3. When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
1) Remove the refrigeration system cartridge. Perform steps 1 through 14 in "IV.B.1.
Recovery Procedure." Once the refrigeration cartridge is out, proceed to step 2.
WARNING
Be careful when handling the cabinet evaporator assembly. This assembly
includes a defrost heater sheathed in a glass tube. This sheathing can be
easily damaged and may also cause cuts if broken. The defrost heater will also
be hot after a defrost. Use gloves when handling and avoid touching the glass
directly. Also prevent the defrost heater from touching other parts.
2) Remove the defrost heater, defrost thermostat, defrost and cabinet thermistors from the
evaporator. See Fig. 3.
3) Remove the evaporator shroud and evaporator bracket from the evaporator.
4) Remove the insulation tubing, and disconnect the evaporator inlet and outlet tubing.
5) Remove the screws holding the evaporator to the refrigeration system cartridge.
6) Remove the evaporator and drier.
7) Place the new evaporator and new drier in position. Provide a safe means for
supporting the evaporator.
Evaporator Shroud
Defrost Thermistor
Evaporator Bracket
Cabinet Fan Motors
Defrost Thermostat
Defrost Heater
Evaporator
Fig. 3
Cabinet Thermistor Bracket
Cabinet Thermistor
48
8) Braze the fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
9) Replace the removed evaporator parts in their correct positions.
10) Once the repair is complete, return to step 15 in "IV.B.1. Recovery Procedure" for
refrigeration system cartridge replacement.
E. Removal and Replacement of Expansion Valve
Moisture in the refrigeration circuit may exceed drier capacity and freeze up at the
expansion valve.
CAUTION
1. Always install a new drier every time the sealed refrigeration system is
opened.
2. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
3. When brazing, protect the valve body and drier by using wet cloths to
prevent the valve body and drier from overheating. Do not allow the valve
body or drier to exceed 250°F (121°C).
1) Move the power switch to the "OFF" position, then unplug the unit.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the insulation and the expansion valve bulb on the suction line.
5) Remove the expansion valve cover and disconnect the expansion valve. Place the new
expansion valve in position.
6) Remove the drier, then place the new drier in position.
7) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
8) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with
pressurized air for leak testing.
9) Evacuate the system and charge it with refrigerant; see the nameplate for the required
refrigerant charge.
10) Attach the expansion valve bulb to the suction line in the same location as the previous
bulb. The bulb should be between the 10 and 2 o'clock position on the tube. Be sure to
secure the bulb with the clamp and holder and to insulate it.
11) Place the expansion valve cover in position.
12) Replace the panels in their correct positions.
13) Plug in the unit, then move the power switch to the "ON" position to start the unit's
cooling process.
49
F. Removal and Replacement of Liquid Line Valve
CAUTION
1. Always install a new drier every time the sealed refrigeration system is
opened.
2. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
3. When brazing, protect the valve body and drier by using wet cloths to
prevent the valve body and drier from overheating. Do not allow the valve
body or drier to exceed 250°F (121°C).
1) Move the power switch to the "OFF" position, then unplug the unit.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the bolt and the solenoid.
5) Disconnect the valve.
6) Place the new valve in position.
7) Remove the drier, then place the new drier in position.
8) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
9) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). DO NOT use R-404A as a mixture with
pressurized air for leak testing.
10) Evacuate the system and charge it with refrigerant; see the nameplate for the required
refrigerant charge.
11) Cut the leads of the solenoid allowing enough lead length to reconnect using closed
end connectors.
12) Connect the new solenoid leads.
13) Attach the solenoid to the valve body and secure it with the bolt.
14) Replace the panels in their correct positions.
15) Plug in the unit, then move the power switch to the "ON" position to start the unit's
cooling process.
50
G. Removal and Replacement of Condenser
CAUTION
1. Always install a new drier every time the sealed refrigeration system is
opened.
2. Do not replace the drier until after all other repair or replacement has been
made. Install the new drier with the arrow on the drier in the direction of the
refrigerant flow.
3. When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
1) Move the power switch to the "OFF" position, then unplug the unit.
2) Remove the panels.
3) Remove the refrigeration system cartridge. Perform steps 1 through 14 in "IV.B.1.
Recovery Procedure." Once the refrigeration system cartridge is out, proceed to step 4.
4) Remove the condenser thermistor (clogged filter).
5) Disconnect the condenser inlet and outlet piping.
6) Remove the condenser assembly.
7) Remove the air guide, evaporator case cover bracket, and condenser shroud (A) from
the old condenser and attach it to the new condenser. See Fig. 4.
8) Place the new condenser assembly in position.
9) Remove the drier, then place the new drier in position.
10) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
11) Replace the condenser thermistor (clogged filter) in its correct position.
12) Once the repair is complete, return to step 15 in "IV.B.1. Recovery Procedure" for
refrigeration system cartridge replacement.
Evaporator Case
Cover Bracket
Condenser
Condenser Shroud (A)
Air Guide
Condenser Thermistor
(clogged filter)
Fig. 4
51
H. Removal and Replacement of Thermistors and Thermostat
CAUTION
1. The thermistors are fragile; handle very carefully.
2. Do not shorten or cut the thermistor leads.
1. Cabinet Thermistor
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.
Pump-Down Procedure." Once the refrigeration system cartridge is out, proceed to
step 2.
2) Cut the cable tie holding the cabinet thermistor to the cabinet thermistor bracket.
Remove the thermistor. See Fig. 5.
3) Disconnect the thermistor wire connector (below the control box).
4) Install the new thermistor and secure it to the cabinet thermistor bracket. Connect the
thermistor connector.
5) Once the repair is complete, return to step 17 in "IV.B.2. Pump-Down Procedure" for
refrigeration system cartridge replacement.
2. Defrost Thermistor
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.
Pump-Down Procedure." Once the refrigeration system cartridge is out, proceed to step
2.
2) Remove the tape securing the defrost thermistor to the evaporator shroud. Cut the
cable tie holding the defrost thermistor to the shroud. Remove the defrost thermistor.
See Fig. 5.
3) Disconnect the defrost thermistor wire connector (below the control box).
4) Install the new defrost thermistor and secure to the evaporator shroud. Connect the
defrost thermistor connector.
5) Once the repair is complete, return to step 17 in "IV.B.2. Pump-Down Procedure" for
refrigeration system cartridge replacement.
Defrost Thermistor
Cabinet Fan
Motors
Defrost Thermostat
Evaporator Shroud
Defrost Heater
Cabinet Thermistor Bracket
Fig. 5
Cabinet Thermistor
52
3. Defrost Thermostat
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.
Pump-Down Procedure." Once the refrigeration system cartridge is out, proceed to
step 2.
2) Disconnect the defrost thermostat wires, then remove the defrost thermostat.
See Fig. 5.
3) Install the new defrost thermostat and connect the thermostat wires.
4) Once the repair is complete, return to step 17 in "IV.B.2. Pump-Down Procedure" for
refrigeration system cartridge replacement.
4. Rail Thermistor
1) Open the front panel. Move the power switch to the "OFF" position, then unplug the
unit.
2) Remove the storage pans from the rail area. If wet, dry the rail area with a dry cloth.
3) Remove the left side rail fan motor shroud. See Fig. 6.
4) Cut the ties securing the rail thermistor to the bracket.
5) Secure the new thermistor connector to the old thermistor in the rail area. DO NOT cut
the new thermistor wire.
6) Remove the wire access hole sealant and grommet.
7) Push the old thermistor wire (with new thermistor wire securely attached) into the
rail channel. Once the new thermistor wire is in the channel, replace the access hole
grommet. Remove the left side panel, then pull the thermistor wire through the rail
channel.
Rail Fan Motor
Shroud
Rail Fan Motor
Bracket
Rail Fan Motor
Rail Thermistor
Rail Thermistor
Fig. 6
8) Disconnect the old thermistor connector from the control box connector, then connect
the new thermistor connector to the control box connector.
9) Secure the new rail thermistor to the bracket with a cable tie.
10) Seal the access hole with food grade silicone.
11) Replace the rail fan motor shroud in its correct position and secure. Make sure all wires
are clear of the fan.
12) Replace the panel and empty storage pans in their correct positions.
13) Plug in the unit, then move the power switch to the "ON" position and the rail switch to
the "NORMAL" position to start the unit's cooling process.
14) Do not place food product in the rail area until the rail section has cooled down.
53
5. Condenser Thermistor (clogged filter)
1) Remove the front panel. Move the power switch to the "OFF" position, then unplug the
unit.
2) Remove the left side panel.
3) Remove the aluminum tape and cut the cable tie securing the thermistor. See Fig. 7.
4) Remove the thermistor. Disconnect the wire connection (below the control box).
5) Install the new thermistor and secure with a cable tie and aluminum tape.
6) Plug in the unit, then move the power switch to the "ON" position to start the unit's
cooling process.
Condenser Thermistor
(clogged filter)
Fig. 7
I. Removal and Replacement of Defrost Heater
CAUTION
Be careful when handling both the old and new defrost heaters. The heaters
are sheathed in glass tubes and can possibly cause cuts if broken. The heater
will also be hot after a defrost. Use gloves when handling. Avoid touching the
glass directly; hold the heaters by the ends.
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.
Pump-Down Procedure." Once the refrigeration system cartridge is out, proceed to
step 2.
2) Remove the defrost heater from the defrost heater bracket. See Fig. 8.
3) Disconnect the defrost heater wires.
4) Carefully remove the defrost heater.
5) Place the new defrost heater into position.
6) Connect the new defrost heater wires.
7) Once the repair is complete, return to step
17 in "IV.B.2. Pump-Down Procedure" for
refrigeration system cartridge replacement.
Defrost Heater Bracket
Fig. 8
Defrost Heater
54
J. Removal and Replacement of Fan Motors
1. Cabinet Fan Motor
CAUTION
Be careful when handling the evaporator shroud assembly. This assembly
includes a defrost heater sheathed in a glass tube. This sheathing can be
easily damaged and may also cause cuts if broken. Heater will also be hot after
a defrost. Use gloves when handling and avoid touching the glass directly. Also
prevent heaters from touching other parts.
1) Remove the refrigeration system cartridge. Perform steps 1 through 16 in "IV.B.2.
Pump-Down Procedure." Once the refrigeration system cartridge is out, return to
step 2.
2) Disconnect the wires to the fan motor, then remove the defrost thermistor, cabinet
thermistor, defrost thermostat, and defrost heater from the evaporator shroud.
3) Remove the evaporator shroud from the evaporator.
4) Remove the fan motor. See Fig. 9.
5) Install the new fan motor.
Note: Confirm that the fan motor wires are sealed with food grade silicone at the motor
housing.
6) Replace the evaporator shroud in its proper position.
7) Replace the removed parts in their correct positions, and connect the fan motor wires.
8) Once the repair is complete, return to step 17 in "IV.B.2. Pump-Down Procedure" for
refrigeration system cartridge replacement.
Cabinet Fan
Motors
Defrost Thermistor
Evaporator Shroud
Cabinet Fan Motors
Defrost Thermostat
Defrost Heater
Cabinet Thermistor
55
Fig. 9
2. Condenser Fan Motor
1) Open the front panel. Move the power switch to the "OFF" position, then unplug the
unit.
2) Remove the left side panel.
3) Disconnect the fan motor wires.
4) Remove the condenser fan motor assembly bolts, then remove the condenser fan
motor assembly. See Fig. 10.
5) Remove the fan motor from the fan motor bracket and remove the fan blade from the
fan motor.
6) Place the fan blade on the new fan motor, then install the new fan motor.
7) Replace the fan motor assembly in its correct position.
8) Connect the fan motor wires.
9) Replace the panels in their correct positions.
10) Plug in the unit, then move the power switch to the "ON" position to start the unit's
cooling process.
Condenser Fan Blade
Condenser Fan Motor
Condenser Fan
Motor Bracket
Fig. 10
Condenser
3. Rail Fan Motor
1) Open the front panel. Move the power switch to the "OFF" position, then unplug the
unit.
2) Remove the storage pans from the rail area. If wet, dry the rail area with a dry cloth.
3) Remove the rail fan motor shroud. See Fig. 11.
4) Disconnect the rail fan motor lead wires at least 6" (15 cm) from the fan motor. Remove
the rail fan motor and bracket.
5) Remove the rail fan motor bracket from the old rail fan motor and place on the new rail
fan motor.
6) Secure the new fan motor wires to the old fan motor wires in the rail area. DO NOT cut
the new fan motor wires.
56
7) Remove the rail access hole sealant and grommet.
8) Push the old fan motor wires (with new fan motor wires securely attached) into the rail
channel. Once the new fan motor wires are in the channel, replace the access hole
grommet. Remove the left side panel, then pull the fan motor wires through the rail
channel.
9) Disconnect and discard the old fan motor wires. Connect the new fan motor wires.
10) Seal the rail access hole with food grade silicone.
11) Place the new rail fan motor and the fan motor shroud in their correct positions and
secure. Make sure all wires are clear of the fan.
12) Replace the panel and empty storage pans in their correct positions.
13) Plug in the unit, then move the power switch to the "ON" position and the rail switch to
the "NORMAL" position to start the unit's cooling process.
14) Do not place food products in the rail area until the rail section has cooled down.
Rail Fan Motor
Rail Fan Motor Shroud
Rail Fan Motor Bracket
Fig. 11
K. Removal and Replacement of Door Gasket
Remove the old gasket by pulling it directly out of the vinyl gasket retainer. Thoroughly
clean the gasket area with mild soap and water prior to installing the new gasket. The
new gasket should be installed at the corners first, then working toward the center at
the top, bottom, and sides. The arrow-shaped portion of the gasket should be firmly
seated in the retainer groove for proper assembly. This can be checked by lifting the
edge of the gasket and observing the engagement.
CAUTION
In order to get a proper gasket fit, it is important not to stretch gasket material
during assembly.
L. Door Re-Hinging and Drawer Conversion
Contact your local Hoshizaki distributor or Hoshizaki Technical Support if door reversing
or drawer conversion is desired.
57
V. Cleaning and Maintenance Instructions
A. Cleaning
WARNING
1. Before cleaning the unit, move the power switch to the "OFF" position and
unplug the unit to prevent electric shock by unexpected entrance of water
into the unit or injury by moving parts.
2. Before cleaning the unit, move all foods into another clean refrigerator or
freezer.
3. Do not splash water directly onto the unit. This might cause short circuit,
electric shock, corrosion, or failure.
4. Do not pour or spray water into the rail area. The rail drain is for condensate
only. Excessive liquid in the rail area could result in electric shock. Be sure to
keep the fans dry.
5. Metal edges can cause cuts. Use care and wear protective gloves when
cleaning.
6. Keep hands clear of fan shrouds when the unit is operating. The rotating fans
might cause injury.
7. Before using a sanitizer such as inert soap and sodium hypochlorite (chlorine
bleach), thoroughly read the manufacturer’s instructions on its proper usage.
IMPORTANT
1. To prevent damage to the painted or plastic surfaces, do not use the
following: thinner, benzine, alcohol, petroleum, soap powder, polishing
powder, alkaline cleaner, acid, scouring pad, and especially those strong
cleaners for use on a ventilating fan or a cooking range. Also, to prevent
corrosion, do not use a chlorine bleach such as sodium hypochlorite on the
stainless steel surfaces.
2. Use a clean cloth for cleaning.
1. Work Surface
Clean the cutting board as often as necessary to maintain a clean, sanitary work surface.
Also clean the worktop space underneath the cutting board as often as necessary to
maintain a clean, sanitary surface. After cleaning, be sure to properly secure the cutting
board with the brackets on the ends of the worktop. Slide the brackets down onto the
cutting board and tighten the screws.
WARNING
Make sure the cutting board is secure. Otherwise, the cutting board could come
off and cause injury.
58
2. Rail and Rail Cover
Spills and splashes should be wiped up promptly to avoid unpleasant odors. Wipe
the interior of the rail and the rail cover regularly with a clean, damp sponge or cloth
containing a neutral cleaner. Do not pour or spray water into the rail area.
WARNING
1. Be sure to support the rail cover when cleaning. Otherwise, the rail cover
could close suddenly and cause injury.
2. Metal edges can cause cuts. Use care and wear protective gloves when
cleaning.
3. Exterior
Wipe the exterior occasionally with a clean, soft cloth. Use a damp cloth containing a
neutral cleaner to wipe off oil or dirt build up.
4. Cabinet Interior
Spills and splashes should be wiped up promptly to avoid unpleasant odors. The
cabinet interior should be cleaned periodically with a mild soap or detergent and warm
water.
5. Door/Drawer Gaskets
Door/drawer gaskets should be cleaned regularly with mild soap and warm water to
remove dirt and grease.
6. Shelves (if applicable)
Remove and clean regularly.
7. Drawers (if applicable)
The drawers can be removed for cleaning either individually or as an entire assembly.
• To remove an individual drawer, first remove all food product from the drawer. Pull
the drawer out to its fully extended position and lift up on the handle to disengage the
drawer. Before removing the drawer, carefully support the rear and front of the drawer
and then slowly remove it from the cabinet.
• To remove the drawer frame assembly, first remove the drawers and then remove
the fasteners in the thermal break and in the rear of the cabinet. Carefully slide the
frame out of the cabinet, making sure not to damage the thermal break. Reinstall in the
reverse order, making sure not to overtighten the screws in the thermal break.
• To remove the drawer slide (center slide containing rollers) for cleaning, rotate the top
of the slide away from the frame while the slide is completely inside the cabinet. Drawer
slides do not require lubrication, but slides should be kept clean and free of food.
Note: Drawer slides are dishwasher safe.
59
B. Maintenance
1. Rail Condensate Pan
The rail condensate pan collects condensate water from the rail. Empty the pan as often
as necessary depending on conditions. Clean the pan at least once a month with a
clean, damp sponge or cloth containing a neutral cleaner.
2. Air Filter
The plastic mesh air filter (located behind the front panel) removes dirt and dust from
the air, and keeps the condenser from getting clogged. As the filter gets clogged,
the unit's performance will be reduced. Check the filter at least twice a month. When
clogged, use warm water and a neutral cleaner to wash the filter. The filter can be
removed by opening the front panel and lifting the filter away from the condenser.
3. Condenser
Check the condenser once a year, and clean if required by following the steps below.
More frequent cleaning may be required depending on location.
WARNING
1. Before cleaning the condenser, move the power switch to the "OFF" position
and unplug the unit to prevent electric shock or injury by moving parts.
2. Before cleaning the condenser, move all foods into another clean refrigerator
or freezer.
3. Condenser fins are sharp. Use care when cleaning.
1) Remove and clean the air filter.
2) Use a brush attachment on a vacuum cleaner to gently clean the condenser fins. Do
not use too much force, otherwise the fins could be damaged.
3) Replace the air filter in its proper position.
4. Power Supply Connection
If the plug or power cord is damaged, contact a Hoshizaki Certified Service
Representative immediately and ask for repairs.
All other maintenance or service on this unit should be performed in accordance with
the Hoshizaki Service Manual by a qualified service technician.
60
C. Shutdown and Long Storage
WARNING
1. When preparing the unit for long storage, prevent the doors/drawers from
closing to reduce the risk of children getting trapped.
2. To reduce the risk of electric shock, do not touch the attachment plug or
switches with damp hands.
3. To unplug the unit, be sure to pull the attachment plug and do not jerk the
power cord. It could be damaged and cause fire or electric shock.
4. When shutting down the unit for more than one week, move the power
switch to the "OFF" position and unplug the unit.
5. Do not plug in/unplug the unit to start/stop operation. Make sure the power
switch is in the "OFF" position before plugging in or unplugging the unit to
help reduce the risk of electric shock.
1) Before shutting down the unit, move food into another refrigerator or freezer.
2) Open the front panel and move the power switch to the "OFF" position. The unit will
shut down.
3) Unplug the unit.
4) Close the front panel.
IMPORTANT
When preparing the unit for long storage, perform the cleaning and
maintenance operations detailed in "V. Cleaning and Maintenance
Instructions."
61
62
Rail Evaporator
Rail Fans
Receiver
Tank
Condenser Fan
Rail Expansion Valve
Rail Liquid
Line Valve
Rail High-Side
Access Valve
Rail High‑Side
Service Valve
Drier
Compressor
Compressor Access Valve
Receiver Service Valve
Cabinet
Expansion
Valve
Cabinet
Liquid
Line
Valve
Rail Low-Side
Access Valve
Rail
Disconnects
Rail Low‑Side
Service Valve
Cabinet
Evaporator
Defrost
Thermistor
Control Box
Note: The number of rail fans varies between models.
Rail Thermistor
Cabinet Fans
Cabinet Thermistor
Defrost Thermostat
Front
Condenser
Cabinet
Condensate
Drain Pan
High Pressure
Switch
VI. Technical Information
A. Refrigeration Circuit
1. HPR46A(-D), HPR72A(-D), HPR100A(-D)
B. Wiring Diagrams
1. HPR46A(-D)
Transformer Output
10V at 115V
*
*High Pressure Switch
63
Cut-out
490±10 PSIG
Cut-in
370±20 PSIG
2a. HPR72A(-D) Auxiliary Code U-5 and Earlier
Transformer Output
10V at 115V
*
*High Pressure Switch
64
Cut-out
490±10 PSIG
Cut-in
370±20 PSIG
2b. HPR72A(-D) Auxiliary Code U-6 and Later
Transformer Output
10V at 115V
*
*High Pressure Switch
65
Cut-out
490±10 PSIG
Cut-in
370±20 PSIG
3. HPR100A(-D)
AWAITING DATA
66
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