Hoshizaki HPR100A Service Manual Download

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2a. HPR72A(-D) Auxiliary Code U-5 and Earlier

*High Pressure Switch

Cut-out

490±10

PSIG

Cut-in

370±20 PSIG

Transformer Output
10V at 115V

Summary of Contents for HPR100A

Page 1: ...Superior Degree of Reliability www hoshizaki com Model Refrigerated Prep Table with Raised Rail Commercial Kitchen Equipment Hoshizaki America Inc Number 73168 Issued 8 12 2009 Revised 5 11 2011 SERV...

Page 2: ...uld 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 HOSH...

Page 3: ...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 Cabi...

Page 4: ...very 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 Val...

Page 5: ...0 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 6...

Page 6: ...t 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 indep...

Page 7: ...or Height mm in Interior Width mm in Interior Depth mm in HPR46A D 1 Section 8 5 12 1040 40 95 816 32 13 1168 4 46 858 5 33 79 640 5 25 22 604 1 23 78 641 8 25 27 HPR72A D 2 Section 18 8 18 1828 8 72...

Page 8: ...r Cabinet Air Duct Refrigeration Cartridge Cabinet Evaporator Assembly Cabinet Thermistor Cabinet Evaporator Fan Motors Cabinet Interior Side Panel Defrost Thermostat Cabinet Defrost Thermistor Conden...

Page 9: ...er 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 Rail...

Page 10: ...rgizes 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...

Page 11: ...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...

Page 12: ...energized CTh warms to setpoint 2 minute Comp delay timer starts 6 hour DT starts 5 Cabinet Cool Down Defrost Recovery defrost terminated CabFM energized CLLV energized Comp energized ConFM energized...

Page 13: ...rgized PH energized RailFM energized RLLV de energized CabFM energized PH energized RailFM energized RLLV energized CLLV de energized Comp de energized ConFM de energized CabFM energized Comp energize...

Page 14: ...nergized PH de energized To 5 below Comp energized ConFM energized RailFM energized RLLV energized CabFM de energized CLLV de energized DH de energized PH de energized C on R on C on R off CLLV energi...

Page 15: ...ch 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 co...

Page 16: ...3 Rail Liquid Line Solenoid Valve RLLV 1 5 Cabinet Liquid Line Solenoid Valve CLLV K311 Connector 1 2 Comp Control Relay Brown 3 4 Cabinet Evaporator Fan Relay Red 5 6 Defrost Heater Relay Orange Chi...

Page 17: ...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...

Page 18: ...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...

Page 19: ...ost 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 wil...

Page 20: ...Section 2 Section 3 Section Cabinet 9 to 9 F in 0 9 F increments 5 to 5 C in 0 5 C increments 0 F 0 C TBD Rail 1 8 F 1 C 0 9 F 0 5 C TBD Negative values are indicated by an LED to the left of the val...

Page 21: ...w 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 t...

Page 22: ...Comp on 0 F 0 C at setpoint Comp off 3 6 F 2 C below setpoint Comp on 0 F 0 C at setpoint Comp off 3 6 F 2 C below setpoint F3 High Temperature Alarm Delay Time See III A Alarm Signals 0 to 3 hours i...

Page 23: ...d 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 pr...

Page 24: ...ween thermistor leads Normal reading is from 5 to 6 5 k for the cabinet rail and defrost thermistors and 145 to 175 k for the condenser thermistor Replace the thermistor if it exceeds the normal readi...

Page 25: ...tions and Adjustments E1 8 High Temperature Alarm cabinet only Cabinet temperature has exceeded the setpoint temperature by 18 F 10 C for more than x hours The default value of x is 2 When the tempera...

Page 26: ...to take action when this alarm activates could result in damage to the compressor E8 3 Defrost Thermistor Malfunction Alarm Defrost thermistor shorted or open After replacing defrost thermistor alarm...

Page 27: ...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 ar...

Page 28: ...s 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 Servi...

Page 29: ...es 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 o...

Page 30: ...e 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 out...

Page 31: ...e 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...

Page 32: ...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 conditi...

Page 33: ...3 Wiring to fan motor 3 Check for loose or open connection and replace 4 Fan blade bound 4 Check and replace b Evaporator Fan Rail Fan or Compressor Relay 1 Bad contacts 1 Check for continuity and rep...

Page 34: ...n contacts 1 Replace j Compressor 1 Open windings 1 Check for continuity and replace 2 Locked rotor 2 Replace k Control Board 1 In alarm or defective 1 See III A Alarm Signals or replace 2 Cabinet Coo...

Page 35: ...rge m Expansion Valve 1 Operating erratically 1 Check and replace n Compressor 1 Defective 1 See 1 3 Compressor will not start or stops operating o Control Board 1 Defective 1 Replace 2 Cabinet temper...

Page 36: ...er 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 closed 1 Confirm service valve is open j Refrigerant 1 Leak 1 Recove...

Page 37: ...Defrost Heater 1 Defective 1 Replace heater d Defrost Thermostat 1 Defective turning off heaters prematurely or fused open 1 Replace defrost thermostat e Cabinet Liquid Line Valve 1 Does not close 1 C...

Page 38: ...ronment and door opening conditions 1 Adjust conditions e Rail Condensate Pan 1 Overflowing 1 Empty and clean rail condensate pan 2 Abnormal Noise a Fasteners 1 Loose fasteners allow vibration of part...

Page 39: ...ressurized 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 replaci...

Page 40: ...TION 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 t...

Page 41: ...ge 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 B...

Page 42: ...ore 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 th...

Page 43: ...8 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 tighte...

Page 44: ...y 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 refrig...

Page 45: ...race 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 E...

Page 46: ...46 Fig 2 Refrigeration Cartridge Cabinet Fan Motors Cabinet Thermistor Defrost Thermistor Defrost Thermostat Defrost Heater Rail Thermistor Cabinet Evaporator Fan Motor Shroud Evaporator Case...

Page 47: ...e 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 sto...

Page 48: ...e 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 ho...

Page 49: ...t 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 exp...

Page 50: ...e 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 d...

Page 51: ...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 th...

Page 52: ...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 Onc...

Page 53: ...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 r...

Page 54: ...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 refrige...

Page 55: ...tep 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...

Page 56: ...ect positions 10 Plug in the unit then move the power switch to the ON position to start the unit s cooling process Condenser Fan Motor Bracket Condenser Fan Motor Condenser Fan Blade Condenser Fig 10...

Page 57: ...nversion is desired 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 i...

Page 58: ...nert 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 fo...

Page 59: ...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 indi...

Page 60: ...ear 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 an...

Page 61: ...or 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 pl...

Page 62: ...Liquid Line Valve Rail Expansion Valve Compressor Compressor Access Valve Cabinet Condensate Drain Pan High Pressure Switch Drier Condenser Fan Condenser Receiver Tank Receiver Service Valve Rail Low...

Page 63: ...63 B Wiring Diagrams 1 HPR46A D High Pressure Switch Cut out 490 10 PSIG Cut in 370 20 PSIG Transformer Output 10V at 115V...

Page 64: ...64 2a HPR72A D Auxiliary Code U 5 and Earlier High Pressure Switch Cut out 490 10 PSIG Cut in 370 20 PSIG Transformer Output 10V at 115V...

Page 65: ...65 2b HPR72A D Auxiliary Code U 6 and Later Transformer Output 10V at 115V High Pressure Switch Cut out 490 10 PSIG Cut in 370 20 PSIG...

Page 66: ...66 3 HPR100A D AWAITING DATA...

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