Hoshizaki DCM-230FE User manual

ISSUED:
HOSHIZAKI
CUBELET ICE DISPENSER
MODEL
DCM-230FE
SERVICE MANUAL
DEC.23,1998
NO: 73109
REVISED: JAN.13,2004

2
HOSHIZAKIAMERICA, INC.
618Highway74South
PeachtreeCity,GA 30269
Attn: HOSHIZAKITechnicalSupportDepartment
Phone: [phone]TechnicalService
[phone]
Fax: [phone]
NOTE: Toexpediteassistance,allcorrespondence/communicationMUST includethefollowing
information:
• ModelNumber
• SerialNumber
• Completeanddetailedexplanationoftheproblem
FOREWORD
IMPORTANT
Only qualified service technicians should attempt to service or maintain this icemaker.
No service or maintenance should be undertaken until the technician has thoroughly
read this Service Manual.
HOSHIZAKI provides this manual primarily to assist qualified service technicians in the
service and maintenance of the icemaker.
Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call or write to the HOSHIZAKI Technical Support Department for
assistance.

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Please review this manual. It should be read carefully before the icemaker is serviced
or maintenance operations are performed. Only qualified service technicians should
service and maintain the icemaker. This manual should be made available to the tech-
nician prior to service or maintenance.
CONTENTS PAGE
I. GENERAL INFORMATION ............................................................................................. 5
1. DIMENSIONS AND CONNECTIONS ........................................................................5
2. CONSTRUCTION ......................................................................................................6
3. OPERATION - How it works ......................................................................................7
4. TIMER BOARD ..........................................................................................................8
[a] SOLID-STATE CONTROL ..................................................................................8
[b] TIMER BOARD ................................................................................................... 8
[c] SEQUENCE ...................................................................................................... 10
II. INSTALLATION INSTRUCTIONS................................................................................12
1. UNPACKING............................................................................................................12
2. LOCATION...............................................................................................................13
3. INSTALLATION ....................................................................................................... 14
4. ELECTRICAL CONNECTION..................................................................................14
5. WATER SUPPLY AND DRAIN CONNECTIONS.....................................................15
III. OPERATING INSTRUCTIONS ....................................................................................17
1. START UP ...............................................................................................................17
2. CONTROLS AND ADJUSTMENTS ......................................................................... 19
3. PREPARING THE ICE DISPENSER FOR LONG STORAGE................................. 19
IV. MAINTENANCE........................................................................................................... 21
1. PERIODIC CLEANING ............................................................................................21
2. CLEANING OF WATER SYSTEM ...........................................................................22
V. TECHNICAL INFORMATION ....................................................................................... 27
1. WATER CIRCUIT AND REFRIGERANT CIRCUIT..................................................27
2. WIRING DIAGRAM.................................................................................................. 28
3. TIMING CHART ....................................................................................................... 29
4. SPECIFICATIONS ................................................................................................... 30
5. PERFORMANCE DATA...........................................................................................31
6. ICE DISPENSING CAPACITY.................................................................................32
VI. SERVICE DIAGNOSIS ...............................................................................................36
VII. REMOVAL AND REPLACEMENT OF COMPONENTS ............................................40
1. SERVICE FOR REFRIGERANT LINES...................................................................40
[a] REFRIGERANT RECOVERY ...........................................................................40
[b] EVACUATION AND RECHARGE (R-404A) .....................................................40
2. BRAZING .................................................................................................................41

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3. REMOVAL AND REPLACEMENT OF COMPRESSOR ........................................... 42
4. REMOVAL AND REPLACEMENT OF DRIER.......................................................... 43
5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE.................................... 44
6. REMOVAL AND REPLACEMENT OF ICE MAKING MECHANISM.............................
AND WATER SYSTEM............................................................................................. 45
7. REMOVAL AND REPLACEMENT OF ELECTRICAL SYSTEM ............................... 51
8. REMOVAL AND REPLACEMENT OF DISPENSING SYSTEM ............................... 53
9. BEFORE CALLING A SERVICE AGENT ................................................................. 54
10. WARRANTY ............................................................................................................. 54

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I. GENERAL INFORMATION
1. DIMENSIONS/CONNECTIONS

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2. CONSTRUCTION
Hoshizaki Cubelet Ice Dispenser, model DCM-230FE includes Water Supply, Freezer,
Condensing, Storage, Dispensing and Control Assemblies.

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3. OPERATION - How it works
Water flows from the potable water source through the Water Supply Line Shut-off Valve,
enters at the Water Inlet fitting and into the Water Reservoir. The Water Reservoir func-
tions to maintain a constant water level inside the Freezer Assembly. Water from the
Water Reservoir enters at the bottom of the Freezer. Heat is removed by the refrigeration
process and ice forms inside the Freezer.
A stainless steel Auger, located inside the Freezer, is direct-driven by the Gear Motor, and
the rotating Auger carries the ice upward to the end of the Auger, where excess water is
pressed out of the ice, as the ice is extruded and broken into cubelet ice (compressed ice)
and then pushed out into the Ice Storage Bin through the Ice Spout.
Turning on the Power Switch on the Control Box starts the automatic and continuous
icemaking process. When the Ice Storage Bin is filled with ice, the Bin Control Switch,
located on the top of the Storage Bin, shuts off the icemaking process. As the ice is re-
moved from the Storage Bin, the Bin Control Switch resets automatically and restarts the
icemaking process.
Moving the Dispense Mode Switch to the “PORTION” position gives the user a portion-
controlled mode, resulting in dispensing a certain amount of ice (See “IV. 2. CONTROLS
AND ADJUSTMENTS”) when the Push Button is pressed. Moving the switch to the “CON-
TINUOUS” position, gives a continuous dispensing mode, resulting in dispensing ice while
the Push Button is being pressed.
The Agitator in the Storage Bin keeps the ice from clustering so that the ice can move
easily through the Spout and prevents the formation of an ice block.

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4. TIMER BOARD
[a] SOLID-STATE CONTROL
1) A HOSHIZAKI exclusive solid-state control is employed in the DCM-230FE cubelet ice
dispenser. This control includes a microprocessor (LSI) developed by HOSHIZAKI.
2) A Printed Circuit Board (hereafter called “Timer Board”) includes a stable and high quality
control system.
3) No adjustment is required.
[b] TIMER BOARD
CAUTION
1. Fragile, handle very carefully.
2. A timer board contains CMOS (Complementary Metal-Oxide Semiconductor)
integrated circuits, which are susceptible to failure due to static discharge. It
is especially important to use an antistatic wrist strap when handling or
replacing the board.
3. Do not touch the electronic devices on the board or the back of the board to
prevent damage to the board.
4. Do not change wiring and connections. Especially, never misconnect K1,
K2, K3 and K4.
5. Do not fix the electronic devices or parts on the board in the field. Always
replace the whole board assembly when it goes bad.
A timer board, Part Code 2U0098-02 (Model H2AA086C03), is used for DCM-230FE.

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KRAMMETIEMIT
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ON
OFF
OFF
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OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
t3 t3
t4
t2
t1
t8 t10
t5
t6 t7
t6 t6
t9 t9
Bin Control
Pressure Switch
Ice Switch
[portion controlled]
Ice Switch
[continuous]
X1 Relay
[Gear Motor]
X2 Relay
[Compressor Relay]
X4 Relay
[Agitating Motor]
X5 Relay
[Solenoid]
[Dispensing Motor]
[c] SEQUENCE

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Functions of Relays
1) X1- makes just when the Bin Control Circuit closes.
- breaks t3 sec. after X2 breaks following the t2 sec. delay since the Bin Control Circuit
opens.
- will not make for t4 sec. after X2 breaks, even if the Bin Control Circuit closes.
2) X2- makes t1 sec. after the Bin Control Circuit closes.
- breaks t2 sec. after the Bin Control Circuit opens.
- will not make while the Pressure Switch is OFF, whether the Bin Control Circuit is ON
or OFF.
3) X4- makes for t10 sec. after the t8 sec. delay since the Bin Control Circuit closes.
- makes for t9 sec. after the t6 sec. delay since X5 is made by switching ON the Ice
Switch (portion controlled) or Ice Switch (continuous).
- makes just when X5 is made by switching ON the Ice Switch (portion controlled) or
Ice Switch (continuous), after t7 min. has passed since X4 breaks.
4) X5- makes for t5 sec. after the Ice Switch (portion controlled) is switched ON.
- is ON while the Ice Switch (continuous) is ON.

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II. INSTALLATION INSTRUCTIONS
WARNING
The installation must be carried out by qualified personnel, in accordance with
current regulations, according to the manufacturer’s instructions.
1. UNPACKING
WARNING
Children should not be allowed in reach of the packaging elements (plastic
bags and expanded polystyrene) as they are potential sources of danger.
CAUTION
1. Removeshippingcarton,tape(s) and packing. Ifpackingmaterialisleftin the
ice dispenser, it will not work properly.
2. Ensureallcomponents,fastenersandthumbscrewsaresecurelyinplace.
1)Afterremovingthe packaging, make sure that the ice dispenser is in good condition. If in
doubt, please do not use the equipment but apply to professionally qualified personnel.
2) Remove the Upper Front, Top and Side Panels to prevent damage when installing the ice
dispenser. See Fig. 1.
3) Remove the package of accessories, and check the contents:
a) Installation Kit
Inlet Hose 1
Outlet Hose 2
1/2-3/4 Nipple 1
3/4-3/4 Nipple 2
b) Bracket 2
c) Fuse 3
4) Check for 10A, 1A and 0.5A spare fuses.
5) Remove the protective plastic film from the panels. If the ice dispenser is exposed to the
sun or to heat, remove the film after the ice dispenser cools.

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2. LOCATION
IMPORTANT
1. This ice dispenser is not intended for outdoor use. Normal operating ambi-
ent temperature should be within +5°C to +40°C. Normal operating water
temperature should be within +5°C to +35°C. Operation of the ice dispenser,
for extended periods, outside of these normal temperature ranges may affect
production capacity.
2. The ice dispenser should not be located next to ovens, grills or other high
heat producing equipment.
3. The location should provide a firm and level foundation for the equipment at
normal counter top height.
4. Allow 15 cm clearance at rear, sides and top for proper air circulation and
ease of maintenance and/or service should they be required.
5. This appliance is not suitable for installation in an area where a water jet
could be used and where dripping is not allowed.
6. Do not place anything on top of the ice dispenser or in front of the Louver.
Upper Front Panel: Remove the screws. Pull the bottom toward you.
Top Panel: Remove the Thumbscrew. Lift up the front and push away.
Apron/Side Panel: Remove the screws and pull toward you.
Fig. 1

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3. INSTALLATION
• Incorrect installation can cause harm to people, animals or things, for which the manufac-
turer cannot be held responsible.
1) Position the ice dispenser in the selected permanent site.
2) Level the ice dispenser in both the left-to-right and front-to-rear directions.
4. ELECTRICAL CONNECTION
WARNING
THIS APPLIANCE MUST BE EARTHED
This ice dispenser requires an earth that meets the national and local electri-
cal code requirements. To prevent possible severe electrical shock to indi-
viduals or extensive damage to equipment, install a proper earth wire to the
ice dispenser. Remove the plug from the mains socket before any mainte-
nance, repairs or cleaning is undertaken.
• This ice dispenser must have a separate power supply or receptacle of proper capacity.
See the Nameplate.
• The main control box fuses are rated at 10A, 1A and 0.5A and should only be replaced
by a qualified service engineer.
• Usually an electrical permit and services of a licensed electrician are required.
• If the supply cord and the plug should need to be replaced, it should only be done by a
qualified service engineer.
For the U.K. and the Republic of Ireland only
• The wires in the mains lead are coloured in accordance with the following code:
Green & Yellow = Earth
Blue = Neutral
Brown = Live
As the colours of the wire in the mains lead of this appliance may not correspond with the
coloured markings identifying the terminals in your plug, proceed as follows:
The wire which is coloured Green-and-Yellow must be connected to the terminal in the
plug which is marked with the letter E or by the symbol or coloured Green or Green-
and-Yellow. The wire which is coloured Blue must be connected to the terminal which is
marked with the letter “N” or coloured Black. The wire which is coloured Brown must be

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connected to the terminal which is marked with the letter L or coloured Red.
• Should the socket outlets in the installation site not be suitable for the plug supplied with
your product, the plug must be removed (cut off if it is moulded on plug) and an appropri-
ate plug fitted.
If the non-rewirable has been cut from the power supply cord, it must be disposed of.
There should be no attempt to reuse it. Inserting such a plug into a socket elsewhere
presents a serious risk of electrical shock.
• The non-rewirable plug must never be used without a fuse cover being fitted.
The correct replacement for the detachable fuse cover is identifiable from the
manufacturer’s reference number stamped on the plug.
Supply of replacement fuse covers can be obtained from Hoshizaki Parts/Service Centres.
Fuses should be rated at 10A and approved to BS 1362.
5. WATER SUPPLY AND DRAIN CONNECTIONS
(FortheU.K.only,theconnectionsmustbeinaccordancewithcurrentrequirementsoftheModel
Water Byelaws 1986 SI No. 1147)
• Only potable water should be used for this ice dispenser.
• Water supply pressure should be minimum 0.5 bar and maximum 8 bar. If the pressure
exceeds 8 bar, use a pressure reducing valve. Do NOT throttle back the supply tap.
• A plumbing permit and services of a licensed plumber may be required in some areas.
• The ice dispenser drain is gravity flow, so ensure drainpipe has an adequate pitch or fall.
• Water should drain into an open trap.
1) By means of a suitable spanner or wrench, tighten the 1/2-3/4 Nipple (accessory) into the
Rc1/2 fitting on the rear of the ice dispenser as indicated. P.T.F.E. tape and/or a suitable
sealing compound should be used to obtain a leak free joint.
Note: Jointing compounds should be approved and suitable for potable water use.
2) Attach angled end of white flexible inlet hose (accessory) to free end of 1/2-3/4 Nipple
ensuring rubber sealing washer is correctly positioned. Hand tighten sufficiently to provide
leak free joint.
3) Attach the other end of inlet hose to the water tap, noting washer is correctly positioned
before hand tightening as above.

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4) Attach grey flexible outlet hoses (accessory) to the R3/4 fittings on the rear bottom of the
ice dispenser, confirming fitment of rubber washers before finally hand tightening the
joints. These pipes can be cut to length as necessary to suit position of main drain.
Fig. 2
Fig. 3

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III. OPERATING INSTRUCTIONS
WARNING
1.Thisicedispenserisdesignedtoproduceandstoreedibleice.Tokeepthe
ice dispenser hygienic:
• Wash your hands before removing ice.
• Keep the Grille in the Tray clean. Clean it by using a neutral cleaner and
rinse thoroughly.
2. The use of any electrical equipment involves the observance of some
fundamental rules. In particular:
• Instances of high humidity and moisture increase the risk of electrical
short circuits and potential electrical shocks. If in doubt, disconnect the
ice dispenser.
• Do not pull the power cord in order to disconnect the ice dispenser from
the feed network.
• This appliance is not suitable for unsupervised use by young children,
aged or infirm persons.
3. All parts are factory-adjusted. Improper adjustments may result in failure.
4. If the unit is turned off, wait for at least 3 minutes before restarting the ice
dispenser to prevent damage to the Compressor.
5. Dispensing no ice for more than 5 or 6 hours could result in spouting wet
ice or making ice bridge. Turn off the Control Switch, and remove ice from
the Storage Bin within 2 hours. Soggy and sticky ice should be removed
continuously as produced.
1. START UP
1) Clean the Storage Bin
2) Open the Water Supply Line Shut-off Valve.
3) Plug in the ice dispenser.
4) Remove the Front Panel.
5) Turn on the Power Switch on the Control Box.

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CAUTION
Be sure that the Control Switch, located at the bottom of the Middle Front
Panel, is moved to the “ICE” position. Verify that the Manual Drain Valve at the
bottom right of the Middle Front Panel is closed.
6) Replace the Front Panel in its correct position.
7) Check that water flows into the Water Supply and the Freezer Assembly:
• Water flows into the Reservoir through the Water Valve.
• Water flows into the Freezer bottom through the Feeder Tubing.
• The Float Switch trips to shut off or close the Water Valve.
8) Check the water supply and drain connections for water leaks.
9) After the Water Valve has closed, the Gear Motor starts first, then the Compressor, and
an automatic and continuous icemaking process starts.
10) In a few minutes, cubelet ice is extruded into the Storage Bin.
11) Check for abnormal noise from the Compressor, Fan Motor or Gear Motor after 30
minutes of running.
12) Move the Dispense Mode Switch, located at the bottom of the Middle Front Panel,
to the “PORTION” or “CONTINUOUS” position.
13) Press the Push Button to dispense ice, and the dispensing mechanism will operate.
14) Press the Push Button to dispense water, and the Water Valve will open.
Fig. 5
Fig. 4

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Fig. 6
IMPORTANT
1. Check the conditions and quality of the ice production.
2. Do not use ice produced in the trial run. It might be contaminated with
foreign matter in the water circuit. Discard or flush down the drain.
2. CONTROLS AND ADJUSTMENTS - Portion Control
• The Portion Control is located on the Control Box to control the amount of ice dispensed.
If adjustment is desired, please contact an authorized Hoshizaki service company.
• The numbers on the label indicate dispensing time (sec.).
• About 35g of ice is dispensed per second.
Note: The Portion Control is factory-adjusted at the minimum dispensing time
[0.6 sec. (about 21g)].
3. PREPARING THE ICE DISPENSER FOR LONG STORAGE
IMPORTANT
Ensureallcomponents,fastenersandthumbscrewsaresecurelyinplace
afteranymaintenanceorcleaningisdonetotheequipment.
WARNING
When shutting off the ice dispenser for an extended time, drain out all
water from the water line and remove the ice from the Storage Bin. The
Storage Bin should be cleaned and dried. Drain the ice dispenser to pre-
vent damage to the water supply line at sub-freezing temperatures, using
air or carbon dioxide. Shut off the ice dispenser until the proper ambient
temperature is resumed.

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1)ClosetheWaterSupplyLineShut-offValve.
2)MovetheChangeSwitch,locatedonthebottomoftheMiddleFrontPanel,tothe
“CONTINUOUS”position.
3)PressthePushButtontodispenseice,andremoveallicefromtheStorageBin.
4)OpentheDrainValveatthebottomoftheMiddleFrontPanel.
5)RemovetheUpperFrontPanel.
6)TurnoffthePowerSwitch.
7)ReplacetheUpperFrontPanelinits correct position, and close the Drain Valveatthe
bottomoftheMiddleFrontPanel.
IMPORTANT
Before operating the dispenser next time, check that the Drain Valve at the
bottom of the Middle Front Panel and the Water Supply Line Drain Valve are
closed, and open the Water Supply Line Shut-off Valve.
Note: When shutting off the ice dispenser at sub-freezing temperatures, run the ice dis-
penser, with the Water Supply Line Shut-off Valve closed, and blow out the water
inlet line, by using air pressure.
Fig. 7