KM-280MAH-E, KM-500MAH-E, KM-630MAH-E
Contents
1. LIE Techiical InformiellO 252 c DP FRA PR UAR RE E Ceo ARE IR HER EID DNO WE Water Circuit Refrigerant Te dps iin cd E 2 500 KM 630MAH E ccce ccce e prt RR kr B Wiring DilagraMS III TT M KM 280MAH E auxiliary codes L 0 through 1 1b KM 280MAH E auxiliary codes M 2 and later KM 500MAH E auxiliary codes 1 0 through 1 20 KM 500MAH E auxiliary codes M 2 and KM 630MAH E auxiliary codes L 0 through 1 3b KM 630MAH E auxiliary codes M 2 and Aiming EE oet toit Dust P pee dept dE IRA sis nien eDim uiae td MM xU RE RAI CAE EUR CRM LS 2 KM 500MA H E 25 15 31 g IBS Pila acm IV Service Diagnosis ELTERN 41 NO C 41 Evaporator is Frozen Up eta sb bee omis 45 lce Prod ction2. 58 Removal and Replacement of Transformer 58 VI Cleaning and Maintenance Instructions 59 A Preparing the Icemaker for Long 59 B Cleaning and Sanitizing Procedures 60 1 Cleaning PrOCeOUte s bate extrae inni 60 2 Sanitizing Procedure Following Cleaning 62 G Manes 6B ian an dele E 63 I Specifications A KM 280MAH E air cooled AC SUPPLY VOLTAGE AMPERAGE MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks FOR THE EUROPEAN MARKET ICE CAPACITY SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED
3. emm KM 500MAH E air cooled T C KM 630MAH E air cooled kx urba rocaanadanaddauduoataenantcanieanteaniemasanns cieneral AM ERE D RERUM ARE oo unc ET ZR SOOM ird S TIVE SONATAS Esato hate e a UI UR hate rape DUC dus BC ODSTEUCDDD S i EGRE ER PORC DEUM ON rara LER Ede vw Fo OON ERE E ER S aa reiche M eO SO MA ta NER E EE EPI ERE QUE OEO 3 KM 630MAH E Cadete Neh od Mea DUM MR UE I Mei Dou EC Cua end IT 1 sea ta 2 Controller BOSE E rape Ebor E ERE Ek eR BING REN MADE NUM EE 4 Controls and Adjustments o oeoboaoto Ron Rr diee et xat EF EE do euo MORD RoR d 5 Checking the Controller ai o D Mechanical BIYXSORIEOL REPRE ER En Pt PROMPT bc Rp Kota ka Dated nO ORO uro due be 2 Explanation of Operation 2 50 0 HORE RD Reve p pru Newest vie Troubleshooting Mechanical Bin Control
4. uu 0g uiu G6E quu og Zu otk 1979 91 uiu 92 6 uu SG SUE 97871 te uu G69 uU O 197 72 TT 9UE L QO 3anl SSAINIVIS Q USEM g 3 3 me 2 3e y 144 7 E lt 0010 SS emod 096 42 uui SOS 1977 61 ldd Z TOU OM CE C BS 2 KM 500MAH E uu uu SEG WW OEZ WW GOL 08 WW G6E 0008 WU OTL WW G7Z WU 97 wu sss 8 1714 1 8 G GL Bugjunoj dani NIVIS 94 9 ida 7 ubg WWOLZ 0 6 0 6 e Se ee V dang uil G69 uu OE 1 B E LE SUE L 8 E uu 096 uu 8 7 9 6 uu 682 8 6 06 8 76V ldd Jeu 3 KM 630MAH E SES 2 05 8 7 SOL H 9 0 90 941 6 OEC 8 676 572 8 6 6 G6E 8 L 08 08 9 6 97 WOLLOS 8 22 569 8 2 10 GSS GOL E b OE 00 8 E 1 M30 GC 9 ida 7 E 68 V SE 268 0409 AlddNS H3MOd 9
5. GREEN YELLOW 230 50 1 THERMSTOR BOARD ae BKO i ONLY AIR COOLED MODEL ONLY WATER COOLED MODEL Pressure Switch Cut out 412 psig 28 4 bar Cut in 327 x 21 psig 22 5 1 5 bar 30 1b KM 280MAH E auxiliary codes M 2 and later WIRE COLOR CODE aon aa BLACK GY GRAY VIOLET YELLOW GrY GREEN YELLOW LBu LIGHT BLUE Y MAGNETIC CONTACTOR FUSE BR BIN CONTROL 10A THERMSTOR JN FLOAT SW ONLY AIR COOLED MODEL Pressure Switch Cut out 412 psig 28 45 bar Cut in 327 x 21 psig 22 5 1 5 bar 31 2a KM 500MAH E auxiliary codes L 0 through M 1 230 50 1 WIRE COLOR CODE RED P ORANGE DBu DARKBLUE GRAY GREEN YELLOW LIGHT BLUE K62 THERMSTOR BK H1 FLOAT SW H2 CONTROLLER BOARD i Fo1 2 8 93 1 START CAP 72 86MFD ONLY AIR COOLED MODEL Pressure Switch Cut out Cut in 412 28 47 bar 327 21 psig 22 5 1 5 bar 32 ae a i m WE ONLY WATER COOLED MODEL
6. C Controller Board 1 Solid State Control a A HOSHIZAKI exclusive solid state control is employed in Modular Crescent Cubers b A printed circuit board hereafter called controller board includes a stable and high quality control system C All models are pretested and factory adjusted 2 Controller Board CAUTION Fragile handle very carefully 2 A controller 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 board Do not touch the electronic devices on the board or the back of the board to prevent damage to the board Do not change wiring and connections Do not misconnect K3 K4 and K5 because the same connector is used for the thermistor white float switch black and mechanical bin control red For machines with thermostat there is no connection on K4 Always replace the whole board assembly when it goes bad Do not short out power supply to test for voltage Controller Board Part Number 2A1410 01 HOS 001A Control Products 10 Pin Features of Control Products E Controller Board a Maximum Water Supply Period 6 minutes Water solenoid valve opening in the defrost harvest cycle is limited by the defrost timer The water valve cannot remain open longer than the maximum period The water valve can close in less than six minutes if the def
7. 2 056 L L V ldd LAIN 91 6 42 004 095 B E LL 682 29 10 B Construction 1 KM 280MAH E Transformer Water Supply Inlet Control Switch Bin Control Thermostat Condenser except models with Mechanical Bin Control Hot Gas Valve Fan Motor Condenser Expansion Valve Compressor Drier Float Switch Control Box Water Pump Mechanical Bin Control except models with Thermostat 2 KM 500MAH E Transformer Spray Tubes Control Switch K Bin Control Thermostat except models with Mechanical Bin Control Expansion Valve Compressor Float Switch Water Pump Mechanical Bin Control except models j with Thermostat 12 Water Supply Inlet Condenser Hot Gas Valve Fan Motor Condenser Drier Control Box 3 KM 630MAH E Transformer Spray Tubes 2 Water Supply Inlet Control Switch Bin Control Thermostat LR B Condenser except models with N d Mechanical Bin Control 4 lt lt T Hot Gas Valve Expansion Valve n Fan Motor 5 gt Condenser Compressor 2 3 2 Float Switch Control Box G Water Pump Mechanical Bin Control except models with Thermostat
8. Always install a new filter drier every time the sealed refrigeration system is Opened Do not leave the system open for longer than 15 minutes when replacing or servicing parts A Service for Refrigerant Lines 1 Refrigerant Recovery The icemaker unit is provided with two refrigerant access valves one on the low side and one on the high side line Using proper refrigerant practices recover the refrigerant from the access valves and store it in an approved container Do not discharge the refrigerant into the atmosphere 2 Evacuation and Recharge R 404A 1 Attach charging hoses a service manifold and a vacuum pump to the system If possible use quick release connectors on the access valves especially the high side IMPORTANT The vacuum level and 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 Never allow the oil in the vacuum pump to flow backward 3 Allow the vacuum pump to pull down to a 29 9 Hg 760 mm Hg vacuum Evacuating period depends on pump capacity 4 Close the low side valve and high side valve on the service manifold 47 5 Disconnect the vacuum pump and attach a refrigerant service cylinder to the high side line Remember to loosen the connection and purge the air from the hose See the nameplate for the required refr
9. Note All brazing connections inside the evaporator case are clear paint coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove coating 48 C Removal and Replacement of Compressor IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made Note When replacing a compressor with a defective winding be sure to install the new start capacitor and start relay supplied with the replacement compressor 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 R 404A except when they use the same lubricant 1 Turn off the power supply and unplug the icemaker 2 Remove the panels 3 Recover the refrigerant and store it in an approved container See V A 1 Refrigerant Recovery 4 Remove the terminal cover on the compressor and disconnect the compressor wiring 5 Remove the discharge and suction pipes using brazing equipment 6 Remove the hold down bolts washers and rubber grommets 7 Slide and remove the compressor Unpack the new compressor package Install the new compressor 8 Attach the rubber grommets of the prior compressor 9 Sandpaper the suction discharge
10. operates i Hot Gas Solenoid 1 Continues to open in 1 Check for power off in Valve freeze cycle and high freeze cycle and temperature safety replace operates 41 1 Continued from j Water Supply Line 1 Water supply off and 1 Check and get previous page water supply cycle does recommended pressure not finish Condenser water 2 Check and get pressure too low or off recommended pressure and pressure control opens and closes frequently to finally operate high temperature safety k Water Solenoid Mesh filter or orifice gets clogged and water supply cycle does not finish 2 Coil winding opened 2 Replace 3 Wiring to water valve 3 Check for loose connection or open and replace Controller Board Defective 1 II C 5 Checking 2 Water continues to Float Switch be supplied and the icemaker will not 2 Leads opened or 2 Check and replace 3 Float does not move 3 Clean or replace i eee b Controller Board 1 Defective 3 Compressor will not a Wash Switch 1 WASH position 1 Move to ICE position operating b High Pressure Control 1 Dirty air filter or 1 Clean condenser 2 Ambient or condenser 2 Reduce temperature water temperature too warm 3 Refrigerant 3 Recharge 4 Refrigerant line or 4 Clean and replace drier 5 Fan not operating 5 See chart A 6 42 3 Continued from c Overloa
11. 3 Check the controller board using the controller board s test program D The output test switch S3 provides a relay sequence test With power OFF place S3 on and switch power to ICE The correct lighting sequence should be none 2 3 4 1 and 4 normal sequence every 5 seconds S3 should remain in the OFF position for normal operation Mechanical Bin Control These instructions are not applicable to models with thermostat 1 Proximity Switch This machine uses a lever actuated proximity switch hereafter called mechanical bin control to control the ice level in the storage bin 2 Explanation of Operation a The startup and shutdown of the ice machine is controlled via the controller board Dip switch number 7 must be in the ON position for the controller board to receive input from the bin control 1 The controller board receives a resistance value input via the red K4 connector from the bin control A resistor wire harness is connected from the bin control to the controller board 2 When the bin control is activated in the bin full position pushed to the right a 15 8 KQ signal will be sent to the control board to shut down the unit 3 When the bin control is in the normal position bin is not full a 7 9 KQ reading is sent to the control board to continue operation 26 b During operation the controller board will only shut down the machine if a 15 8 KQ signal is received from the bin con
12. OFF position 3 Wait 3 minutes 4 Move the control switch to the ICE position 5 When all the ice from the previous ice making cycle has defrosted from the evaporator approximately 2 minutes close the potable water supply line shut off valve and open the line drain valve 6 Use compressed air or carbon dioxide to blow any remaining water from the pipes 7 Move the control switch to the OFF position 8 Turn off the power supply 9 Close the potable water drain valve 10 Drain the water tank by removing the base cover and one end of the pump tubing See Fig 4 Pump Tubing Do not pull out this side 11 Replace the removed parts in their correct positions Fig 4 59 12 Remove all ice from the storage bin and clean the storage bin 13 Refit the front panel in its correct position B Cleaning and Sanitizing Procedures WARNING HOSHIZAKI recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water conditions TO prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners Always wear suitable protection e g liquid proof gloves eye protectors etc for safe handling of the cleaner and sanitizer Use the cleaners and sanitizers recommended by Hoshizaki Contact your local Hoshizaki office for further details The instructions below give an example of those recommended cleaners and s
13. 0 MAGNETIC CONTACTOR 193 12 1 88 10880 FLOAT SW 0 0 BK BR R ers 93 on o8 91 o6 0 080 2 R I 96 14 03 55 7 YI i P BK HOTGAS WATER cap AR Hi R VALVE KC2 PRESS 65 ME Gy 1 Y ME BE Y y BK 2 5 KC3 KB2 O4 0000 eR BK TRANSFORMER ONLY AIR COOLED MODEL Pressure Switch 21 1 Cut out 412 psig 28 47 bar Cut in 327 21 psig 22 5 1 5 bar 35 C Timing Chart When control switch is turned OFF pressure switch is OFF thermistor temperature exceeds t1 or bin control is in full position during first 5 minutes of freeze cycle for mechanical bin control only 1 From defrost cycle To defrost cycle If float switch is OFF Too High Too Low Temp Temp Thermistor 15 Temperature Float Switch a Compressor Control Icemakin Switch in Pump Motor ICE m Thermostat 5 Fan Motor ON Pressure Water Valve 2 7 Gas Protect Reset PO nm 1 1 Mechanical Bin Control Only The bin control will only shut off the ice machine during the first five minutes of the freeze cycle 2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See 1 4 Controls and Adjustments 36 To stand by cycle When control switch is
14. Alarm Buzzer TEL Microprocessor Will indicate Board revision level on attached label last 2 digits Power LED Lights up when power is supplied to the Board Connector K5 black Float Switch Part Number Pins 1 through 10 1 9 Magnetic Contactor 2 Hot Gas Valve 3 Line Valve 4 Pump Motor icemaking 5 Pump Motor drain 6 Water Valve 7 10 Power line Bin Control 8 Open Relg LED S 4 Switch for C Board Indicate which and ALPINE Board Transformer Connector FS Relays are energized Service Boards only Control Products HOS 001A Board 18 3 Sequence 1st Cycle 1 Unit energized and control switch to ICE 3 Thermistor reads 9 C position Water supply cycle starts Defrost timer starts counting 2 After 1 minute defrost cycle starts WATER VALVE WATER VALVE HOT GAS VALVE FREEZE CYCLE 4 IMPORTANT Water valve opening is limited to 6 minutes PUMP amp FAN 5 After the first 5 minutes in freeze cycle 4 Defrost timer stops counting Defrost cycle is completed and freeze cycle starts Ready to complete freeze cycle when float switch circuit opens IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in freeze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes eve
15. gt 147 5 The voltage safety automatically resets when voltage is corrected The Output Test switch S3 provides a relay sequence test With power OFF place S3 ON and switch power to ICE The correct lighting sequence should be none 2 3 4 1 amp 4 normal sequence every 5 seconds The LEDs are not in numerical order on the board See the diagram on the next page for the location and numbering of LEDs S3 should remain in the OFF position for normal operation The application switch located between relay X3 amp X4 must be set to match the original board application Place this switch in the ALP position if there is no white wire supplied to the K1 connector If there is a white wire place the switch in the C position If this switch is placed in the wrong position either the compressor contactor will remain energized with the control switch OFF or the unit will not start The dip switches should be adjusted per the adjustment chart in II C 4 Controls and Adjustments Number 8 must remain in the OFF position Dip Switch Output Test Switch Used to test Relays on Board Alarm Reset Switch 0008810 OUTPUT TEST 1 Backup Freeze Timer LED Connector K3 white Defrost Control eaters Thermistor Connector K4 red Connected for mechanical bin control models only not connected when used with thermostat bin control Backup Defrost Timer LED
16. 2b KM 500MAH E auxiliary codes M 2 and later WRE COLOR CODE gua ot GRAY VOLET GREEN YELLOW LBu LIGHT BLUE THERMSTOR BOARD FLOAT SW Bare ONLY AIR COOLED MODEL Pressure Switch Cut out 412 psig 28 457 bar Cut in 327 21 psig 22 5 1 5 bar 33 o 5 6 3a KM 630MAH E auxiliary codes L 0 through M 1 WIRE COLOR CODE 5 BROWN 10 ORANGE V VIOLET WITE YELLOW PINK LIGHT BLUE RED DBU Der Gry GREEN YELLOW 230 501 POWER SUPPLY occ L BR N gU CONTROLLER 1 c THERMISTOR 1 BOARD E BR LU 21 e BIN CONTROL 1 START CAP 0 1 0 MAGNETIC CONTACTOR T R 88 004 STARTER FLOAT SW In 11 STARTER BK TRANSFORMER ONLY AIR COOLED MODEL Pressure Switch Cut out 412 psig 28 457 bar Cut in 327 21 psig 22 5 1 5 bar 34 3b KM 630MAH E auxiliary codes M 2 and later WIRE COLOR CODE 230 50 1 POWER SUPPLY gt L See BR LBU CONTROLLER ae lo BIN CONTROL BOARD 1 BR er 9 oj 6 I START CAP
17. 4 M re 73 237 20n MODULAR CRESCENT CUBER KM 280MAH E KM 500MAH E KM 630MAH E SERVICE MANUAL FOR QUALIFIED SERVICE PERSON 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 HOSHIZAKI CARE for assistance TEL 44 0 1707322493 FAX 44 0 1707322315 Hoshizaki Care Branch Offices Benelux TEL 31 0 206918499 FAX 31 0 206918768 Germany TEL 49 0 215492810 FAX 49 0 2154928128 France TEL 33 0 148137130 FAX 33 0 148130992 Note To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem Please review this manual It should be read carefully before the icemaker is serviced or maintenance operations performed Only qualified service technicians should service and maintain the icemaker This manual should be made available to the technician prior to service or maintenance CONTENTS l Specifications sereen a ae Mo Mos cp
18. A Thermostat Hermetic Model 94552 Air cooled Fin and Tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 1 Ibs 10 oz 7359 High 467 PSIG Low 230 PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin VOLTAGE RANGE 198 254 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice C KM 630MAH E air cooled AC SUPPLY VOLTAGE 220 240 50 1 AMPERAGE 9A 5Min Freeze AT 104 F WT 80 F MINIMUM CIRCUIT AMPACITY 15A MAXIMUM FUSE SIZE 15A APPROXIMATE ICE PRODUCTION Ambient PER 24 HR Temp F 50 7 Ibs day kg day 70 Reference without marks 80 587 266 513 233 463 210 90 576 261 460 209 406 184 100 568 258 447 203 357 162 10 10 C 20 15 C 30 25 C 701 318 611 277 461 209 FOR THE EUROPEAN MARKET ICE CAPACITY Ibs day kg day SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL COOLING
19. EJECTION FROM CONDENSER 8159 BTU h AT 90 F 32 C WT 70 F 21 C Note Pressure data is recorded at 5 minutes into freeze cycle The data not in bold should be used for reference only We reserve the right to make changes in specifications and design without prior notice 38 2 KM 500MAH E APPROXIMATE ICE AMBIENT TEMP WATER TEMP F C PRODUCTION PER 24 HR F C 50 10 70 21 90 32 70 21 80 27 90 32 Ibs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 TOTAL HEAT OF REJECTION 7371 BTU h AT 90 F 32 WT 70 F 21 C Note Pressure data is recorded at 5 minutes into freeze cycle The data not in bold should be used for reference only We reserve the right to make changes in specifications and design without prior notice 39 3 KM 630MAH E APPROXIMATE ICE AMBIENT TEMP WATER TEMP F C PRODUCTION PER 24HR rro 70 21 80 27 90 32 Ibs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day m day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 m
20. NT Water valve opening is limited to 6 minutes PUMP amp FAN 4 After the first 5 minutes in freeze cycle 3 Defrost timer stops counting Defrost cycle is completed and freeze cycle starts Ready to complete freeze cycle when float switch circuit opens IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in freeze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes even if defrost timer does not stop counting 21 4 Controls and Adjustments The dip switch is factory adjusted to the positions outlined below For models with mechanical bin control Switch 1 2 3 4 5 6 7 8 9 10 KM 280MAH E ON OFF ON OFF ON OFF OFF OFF OFF OFF OFF OFF ON ON OFF KM 630MAH E OFF OFF OFF OFF OFF OFF ON OFF ON OFF For models with bin thermostat Dip Switch 1 2 3 4 5 6 7 8 9 10 Switch Nos 1 and 2 Used for adjustment of the defrost timer The defrost timer starts counting when the thermistor reads a certain temperature at the evaporator outlet Switch Nos 3 and 4 Used for adjustment of the drain timer When a freeze cycle is completed the pump motor stops and resumes operation in reverse after 2 sec
21. OPERATING CONDITIONS 220 240 50 1 5 1 A 5 Min Freeze AT 104 F WT 80 F MINIMUM CIRCUIT AMPACITY 15A WATER TEMP F 70 50 70 9 258 117 231 105 204 93 15A Ambient 70 80 90 100 10 10 C 21 15 30 25 C 304 138 252 114 178 81 Crescent Cube 4 7 lbs 2 16 kg 240 pcs N A 90 70 F 70 50 F 802 11 6 763 7 1 59 35 3 99 38 3 22 x 27 3 8 x 30 5 16 560 x 695 x 770 mm Stainless Steel Galvanized Steel Rear Net 151 Ibs 69 kg Shipping 175 Ibs 80 kg Cord Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Pipe Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic 94382 Air cooled Fin and tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 12 340g High 467 PSIG Low 230 PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin VOLTAGE RANGE 198 254 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice B KM 500MAH E air cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without ma
22. WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED Crescent Cube 14 3 Ibs 6 5 kg 720 pcs N A 90 70 F 70 50 F 1399 7 3 1300 5 0 153 33 2 208 33 3 22 x 27 3 8 x 37 7 16 560 x 695 x 950 mm Stainless Steel Galvanized Steel Rear Net 165 Ibs 75 kg Shipping 185 Ibs 84 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Pipe Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model RS64C2E IAZ 219 Air cooled Fin and Tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 1165 635g High 467 PSIG Low 230 PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin OPERATING CONDITIONS VOLTAGE RANGE 198 254 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice ww GES uu gez 9i 6 1 General Information imensions A D 1 KM 280MAH E
23. and process pipes 10 Place the compressor in position and secure it using the bolts and washers 11 Remove plugs from the suction discharge and process pipes 12 Braze the process suction and discharge lines Do not change this order while purging with nitrogen gas flowing at a pressure of 3 to 4 psig 21 to 28 bar 13 Install the new filter drier See V D Removal and Replacement of Drier 14 Check for leaks using nitrogen gas at 140 psig 9 65 bar and soap bubbles 15 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge See V A 2 Evacuation and Recharge R 404A 49 16 Connect the terminals and replace the terminal cover in its correct position 17 Replace the panels in their correct positions 18 Plug in the icemaker Turn on the power supply D Removal and Replacement of Drier IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Turn off the power supply Unplug the icemaker 2 Remove the panels 3 Recover the refrigerant and store it in an approved container See V A 1 Refrigerant Recovery 4 Remove the drier 5 Install the new drier with the arrow on the drier in the direction of the refrigerant flow Use nitrogen gas at a pressure of 3 to 4 psig 21 to 28 bar when brazing the tubings 6 Che
24. anitizers 5 Never mix cleaning and sanitizing solutions in an attempt to shorten cleaning time 6 Wipe off any splashed or spilt cleaner sanitizer immediately 1 Cleaning Procedure 1 Mix 3 gallons 11 4 I of water with Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc or Hoshizaki Cleaner Rector Seal Corp using a mixing rate as recommended on the package 2 Remove all ice from the evaporator and the storage bin Note To remove cubes on the evaporator turn off the power supply and turn it on after 3 minutes The defrost cycle starts and the cubes will be removed from the evaporator 3 Turn off the power supply 4 Remove the front panel and then remove the insulation panel by lifting the panel slightly and pulling it toward you 5 Remove the base cover 6 Drain the water tank by removing one end of the pump tubing See Fig 5 Pump Tubing 7 Refit the pump tubing in its correct position Fig 5 Do not pull out this side 60 8 Pour the cleaning solution into the water tank 9 Move the control switch on the control box the WASH position 10 Refit the insulation panel and the front panel in their correct positions 11 Turn on the power supply and start the washing process 12 Turn off the power supply after 30 minutes 13 Remove the front panel and the insulation panel 14 Drain the water tank See step 6 above 15 Refit the pump tubing in its correc
25. ck for leaks using nitrogen gas at 140 psig 9 65 bar and soap bubbles 7 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge See V A 2 Evacuation and Recharge R 404A 8 Replace the panels in their correct positions 9 Plug in the icemaker Turn on the power supply 50 E Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigerant circuit exceeds the drier capacity and freezes up at the expansion valve Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Turn off the power supply Unplug the icemaker 2 Remove the panels 3 Recover the refrigerant and store it in an approved container See V A 1 Refrigerant Recovery 4 Remove the insulation and the expansion valve bulb on the suction line 5 Remove the expansion valve cover and disconnect the expansion valve using brazing equipment Protect adjacent components from excessive heat using damp cloths or similar 6 Braze the new expansion valve with nitrogen gas flowing at a pressure of 3 to 4 psig 21 to 28 bar WARNING 1 Do not heat the wall Place a steel barrier for protection 2 Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 121 C 7 Install the ne
26. d Protector 1 Bad contacts 1 Check for continuity 3 3 Recharge P er 4 Line valve continues to 4 Check line valve s close in freeze cycle operation in freeze and overload protector cycle and replace operates d Starter 1 Check and replace 2 Coil winding opened 2 Replace Start Capacitor or Run Defective Replace P em f Magnetic Contactor 1 Bad contacts Check for continuity 2 Coil winding opened 2 Replace g Compressor 1 Wiring to compressor 1 Check for loose connection or open and replace 3 Protector tripped 3 Reduce temperature h Controller Board 1 Defective 1 See II C 5 Checking 4 Water continues to a Water Solenoid Valve 1 Diaphragm does not 1 Check for water leaks cycle Controller Board Defective See II C 5 Checking 5 No water comes from a Water Supply Line 1 Water pressure too low 1 Check and get spray tubes Water and water level in water recommended pressure pump will not start or tank too low freeze cycle time is Water Solenoid Valve 1 Dirty mesh filter too short orifice and water level in water tank too low c Water System 1 Water leaks 1 Check connections for water leaks and replace 3 Pump out check valve 3 Check assembly and leaking by clean 43 5 Continued from d Pump Motor 1 Motor winding opened 1 Replace 3 Wiring to pump motor 3 Check for loose connection or ope
27. e water solenoid valve water system pump motor and controller board c Pump Out Check 1 Dirty 1 Clean 2 Cloudy or irregular a See chart B 1 and B 3 and check float switch water solenoid valve cubes controller board spray tubes water system refrigerant charge and expansion valve c Water Quality 1 High hardness or 1 Install a water softener contains impurities or filter E Other 1 Icemaker will not a Bin Control Thermostat 1 Set too cold 1 Adjust warmer UD hanical bi stop when bin is filled For mechanical bin 2 Defective 2 Replace with ice control see 11 0 3 2 Abnormal noise a Pump Motor 1 Bearings worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade 3 Fan blade does not 3 Replace move freely Compressor 1 Bearings worn out or 1 Replace merae 74 00 2 Mounting pad out of 2 Reinstall d Refrigerant Lines 1 Rub or touch other lines 1 Replace 1 Plugged often melts b Icemaker and Bin 1 Drains not run 1 Separate the drain Drains separately lines 46 V Removal and Replacement of Components IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after the equipment is serviced IMPORTANT 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
28. eco cod eut 46 DX AbhottfialTG8s idc tito Aas eters i tea 46 ADIE ML LA dM E E 46 V Removal and Replacement 47 A Service for Refrigerant 47 1 Refrigerant HecoVBIY 47 2 Evacuation and Recharge 404 47 rd EH 49 C Removal and Replacement of 49 D Removal and Replacement of nn trrttrrrnenntnn nnn nnnnnne 50 E Removal and Replacement of Expansion Valve 51 Removal and Replacement of Hot Gas Valve 52 G Removal and Replacement of 53 Removal and Replacement of 54 Removal and Replacement of Fan Motor 55 J Removal and Replacement of Water 56 Removal and Replacement of Pump 56 Removal and Replacement of Float 57 M Removal and Replacement of Spray
29. hecking the Controller Board 1 Visually check the sequence with the icemaker operating 2 Visually check the controller board by using the following procedures i Adjust the defrost timer to minimum position Disconnect the thermistor K3 from the controller board Connect a 1 5 3 5 resistor to the connector pins 1 and 2 and energize the unit After the 1 minute 5 second water supply cycle and the 2 minute 10 second defrost cycle the unit should start the freeze cycle 25 ii After the above step i disconnect the float switch leads K5 from the controller board iii within the first 5 minutes of the freeze cycle The unit should go into the defrost cycle after the first 5 minutes 20 seconds of the freeze cycle Reconnect the float switch connector to the controller board After the first 5 minutes of the freeze cycle disconnect the float switch leads from the controller board At this point the unit should start the defrost cycle iv After step iii de energize the unit and confirm that the defrost timer is in the minimum position Disconnect the resistor from the controller board and energize the unit After the 1 minute water supply cycle the defrost cycle starts Re connect a 1 5 kQ 3 5 kO resistor to the connector K3 pins 1 and 2 after the first 2 minutes of the defrost cycle The unit should start the freeze cycle after 1 minute 5 seconds from the resistor connection
30. ice a month When it is clogged use warm water and a neutral cleaner to wash the filter 4 Condenser Check the condenser once a year and clean if required by using a brush or vacuum cleaner More frequent cleaning may be required depending on the location of the icemaker 63
31. igerant charge Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No 700 88 be used 6 A liquid charge is recommended for charging an R 404A system Invert the service cylinder Open the high side service manifold valve 7 Allow the system to charge with liquid until the pressures balance 8 If necessary add any remaining charge to the system through the low side Use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low side access port with the unit running 9 Close the two refrigerant access valves and disconnect the hoses and service manifold 10 Cap the access valves to prevent a possible leak B Brazing DANGER Refrigerant R 4044 itself is not flammable at atmospheric pressure and temperatures up to 80 C Refrigerant R 4044 itself is not explosive or poisonous However when exposed to high temperatures open flames R 404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere Do not use silver alloy or copper alloy containing arsenic Do not use R 404A as a mixture with pressurized air for leak testing Refrigerant leaks can be detected by charging the unit with a little refrigerant raising the pressure with nitrogen and using an electronic leak detector
32. in 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 TOTAL HEAT OF REJECTION 10375 BTU h AT 90 F 32 C WT 70 F 21 C Note Pressure data is recorded at 5 minutes into freeze cycle The data not in bold should be used for reference only We reserve the right to make changes in specifications and design without prior notice 40 IV Service Diagnosis A No Ice Production 1 The icemaker will not Power Supply 1 OFF position 1 Move to ON position 3 Bad contacts 3 Check for continuity p 4 Voltage too high 4 Check and get enon tg b Fuse Inside fused 1 Blown 1 Check for short circuit Conto Switch 2 Bad contacts 2 Check for continuity d Bin Control Thermostat 1 Tripped with bin filled 1 Remove ice P a RN For mechanical 2 Ambient temperature 2 Increase ambient 3 Set too warm 3 See II C 4 Controls and Adjustments f Bin Control 5 Bad contacts orleaks 5 Check for continuity e High Pressure Control 1 Bad contacts 1 Check for continuity f Transformer 1 Thermal fuse blown or 1 Replace ele ae g Wiring to Controller Loose connections or 1 Check for continuity Thermistor Leads short circuit or 1 See II C 4 Controls open and high and Adjustments a temperature safety Defrost Control
33. in the icemaker Turn on the power supply and check for leaks 12 Replace the base cover in its correct position 13 Replace the front panel in its correct position L Removal and Replacement of Float Switch 1 Turn off the power supply Unplug the icemaker 2 Remove the front panel 3 Remove the base cover 4 Drain the water tank by removing one end of the pump tubing See Fig 3 Refit the hose back into position 5 Remove the black rubber connector from the base of the float switch 6 Remove the screws securing the float switch bracket and Pump Tubing the stainless steel adjusting guide 7 Take off the hose sleeving the float switch leads Do rot pul out is side Fig 3 8 Sleeve the leads of the new float switch with the hose 9 Install the new float switch and replace the removed parts in the reverse order of which they were removed 10 Plug in the icemaker Turn on the power supply and check for leaks 11 Replace the base cover in its correct position 12 Replace the front panel in its correct position 57 M Removal and Replacement of Spray Tubes 1 Turn off the power supply Unplug the icemaker 2 Remove the front panel and the insulation panel 3 Remove the rubber hoses from the spray tubes water supply pipe 4 Release the clamps and disconnect the rubber hoses 5 Remove the spray tubes by squeezing the side tabs 6 Install the new spray tubes and replace the removed parts in the reve
34. izing process 6 Turn off the power supply after 15 minutes 7 Remove the front panel 8 Drain the water tank See step 6 in 1 Cleaning Procedure 9 Refit the pump tubing in its correct position 10 Repeat the above steps 16 through 27 in 1 Cleaning Procedure two times to rinse thoroughly 11 Move the control switch to the ICE position 12 Replace the front panel and the base cover in their correct positions 13 Clean the storage bin with water 14 Turn on the power supply and start the automatic icemaking process 62 C Maintenance IMPORTAN This icemaker must be maintained individually referring to the instruction manual and labels provided with the icemaker 1 Stainless Steel Exterior To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up 2 Storage Bin and Scoop Wash your hands before removing ice Use the plastic scoop provided The storage bin is for ice use only Do not store anything else in the bin Keep the scoop clean Clean it by using a neutral cleaner and rinse thoroughly Clean the bin liner by using a neutral cleaner Rinse thoroughly after cleaning 3 Air Filter A plastic mesh air filter removes dirt or dust from the air and keeps the condenser from getting clogged As the filter becomes clogged the icemaker s performance will be reduced Check the filter at least tw
35. l the new drier 8 Check for leaks using nitrogen gas at 140 psig 9 65 bar and soap bubbles 9 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge See V A 2 Evacuation and Recharge R 404A 10 Cut the leads of the solenoid allowing enough lead length to reconnect using closed end connectors 11 Connect the new solenoid leads 12 Attach the solenoid to the valve body and secure it with a screw 52 13 Replace the panels in their correct positions 14 Plug in the icemaker Turn on the power supply G Removal and Replacement of Evaporator IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Turn off the power supply Unplug the icemaker 2 Remove the panels and the top and front insulation from the evaporator 3 Recover the refrigerant and store it in an approved container See V A 1 Refrigerant Recovery 4 Remove the spray tubes and the insulations at the U shaped notch where the refrigeration tubings go through the chassis 5 Remove the insulation tube and disconnect the evaporator inlet tubing at the tee next to the expansion valve using brazing equipment Protect the valve from excessive heat 6 Lift up the evaporator and disconnect the evaporator outlet tubing 7 Install the new evaporator with ni
36. ler board checks the position of the float switch at the end of the initial one minute water fill cycle and at the end of each defrost cycle If the float switch is in the up position electrical circuit closed the controller board changes to the ice making cycle If the float switch is in the down position electrical circuit open the controller board changes to a one minute water fill cycle before starting the ice making cycle This method allows for a low water safety shut down to protect the water pump from mechanical seal failure e High Voltage Cut out control voltage gt 147Vac 5 The maximum allowable supply voltage of this icemaker is limited by the high voltage cut out If miswiring causes excessive voltage on the controller board the high voltage cut out shuts down the circuit in 3 seconds and the icemaker automatically stops When the proper supply voltage is resumed the icemaker automatically starts running again The control board will signal this problem using 7 beeps every 3 seconds f LED Lights and Audible Alarm Safeties The red LED indicates proper control voltage and will remain on unless a control voltage problem occurs At startup a 5 second delay occurs while the board conducts an internal timer check A short beep occurs when the power switch is turned ON or OFF 15 The green LEDs 1 4 represent the corresponding relays and energize and sequence 5 seconds from initial startup as follows ee EX vun T Minu
37. n and replace 4 Defective capacitor 4 Replace 5 Defective or bound 5 Replace and clean impeller out e Controller Board 1 Defective 1 See 5 Checking the Controller Board 6 Fan motor will not a Fan Motor 1 Motor winding opened 1 Replace start or is not 2 Bearing worn out 2 Replace operating 3 Wiring to fan motor 3 Check for loose connection or open and replace 4 Defective capacitor 4 Replace 5 Fan blade bound 5 Check and replace Controller Board Defective See 1 5 Checking 7 All components run a Refrigerant Undercharged Check for leaks and produced 2 Air or moisture trapped 2 drier aa a b Compressor 1 Defective valve 1 Replace c Hot Gas Solenoid 1 Continues to open in 1 Check and replace Valve freeze cycle 44 B Evaporator is Frozen Up 1 Freeze cycle time is a Float Switch too long defective switch 2 Float does not move 2 Clean or replace close with icemaker off c Controller Board 1 Defective 1 See II C 5 Checking fall into bin in harvest recommended pressure cycle c Water Filter System if 1 Dirty Restricted 1 Replace filter d Water Solenoid Valve ME er orifice 2 Diaphragm does not 2 Scu NE for water leaks e Ambient and or water 1 Too cool Increase temperature Fl nna Thermistor O
38. n if defrost timer does not stop counting 19 2nd Cycle and after with pump drain IMPORTANT Freeze cycle time is limited by the freeze timer factory setting even if the float switch does not open Float switch opens and signals to complete 2 Drain timer stops counting freeze cycle Pump drain is completed Drain timer starts counting DRAIN PUMP HOT GAS VALVE SES DEFROST 3 Thermistor reads 9 C Defrost timer starts counting gt K IMPORTANT Water valve e opening is limited to 6 minutes X m 4 Defrost timer stops counting Defrost cycle is completed and freeze cycle starts 5 After the first 5 minutes in freeze cycle Ready to complete freeze cycle when float switch circuit opens IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in freeze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes even if defrost timer does not stop counting 20 2nd Cycle and after with no pump drain IMPORTANT Freeze cycle time is limited by the freeze timer factory setting even if the float switch does not open 1 Float switch opens and signals to complete 2 Thermistor reads 9 C freeze cycle Defrost timer starts counting WATER VALVE M 9 DEFROST 2 IMPORTA
39. ntroller board when the lever is in the bin full position far right If this reads approximately 7 9 KQ the resistors may be miswired Switch the black and white wires in the terminal housing or order a replacement wire harness b Check the stainless steel bracket that the bin control is mounted to c If the preceding items do not resolve the problem replace the bin control assembly 27 lll Technical Information A Water Circuit and Refrigerant Circuit 1 KM 280MAH E Spray Tube Condenser Water High Pressure Switch N Water Supply TIG M a m Evaporator Drier Thermistor Insulation Strainer Hot Gas Valve Discharge Line Compressor Refrigerant Circuit Expansion Valve Water Circuit Drain Valve 28 2 KM 500MAH E KM 630MAH E Spray Tubes Condenser Water Valve High Pressure Switch Water Supply gt lt 5 Evaporator Drier Thermistor Cleanin 9 Insulation Valve Tube Strainer Access Valve Discharge Line Compressor Drain Access Valve Expansion Valve Refrigerant Circuit Drain Valve Water Circuit B Wiring Diagrams 1a KM 280MAH E auxiliary codes L 0 through M 1 WIRE COLOR CODE BR BROWN W WHITE DBu DARKBLUE BLACK GY GRAY V VOLET Y YELLOW
40. off valve 3 Remove the top panel and front panel 4 Remove the valve outlet tubing by releasing the clamp 5 Remove the bracket from the unit 6 Remove the fitting nut and water valve Do not lose the packing gasket 7 Disconnect the terminals from the water valve 8 Install the new water valve and replace the removed parts in the reverse order of which they were removed 9 Open the water supply line shut off valve 10 Plug in the icemaker Turn on the power supply 11 Check for leaks 12 Replace the top and front panels in their correct positions K Removal and Replacement of Pump Motor Note When replacing a pump motor with defective winding it is recommended that a new capacitor be installed 1 Turn off the power supply Unplug the icemaker 2 Remove the front panel 3 Remove the base cover 4 Drain the water tank by removing one end of the pump tubing See Fig 2 Refit the hose back into position 5 Disconnect the pump suction and discharge hoses 6 Remove the closed end connectors from the ER pump motor leads 7 Remove the two screws to remove the pump complete bo not put out this side with the bracket Remove the bracket from the pump 56 Fig 2 8 Remove the pump housing and check the impeller 9 If the impeller is defective install a new impeller 10 Install the new motor or new parts and replace the removed parts in the reverse order of which they were removed 11 Plug
41. onds Then the pump motor drains the water tank for the time determined by the drain timer The drain timer also determines the time to restrain completion of a defrost cycle i e the minimum defrost time Switch Nos 5 and 6 Used for adjustment of the drain counter The pump motor drains the water tank at the frequency determined by the drain counter Switch No 7 Used only on models with mechanical bin control Should be ON for models with mechanical bin control and OFF for models with bin thermostat Switch No 8 Used only for checking the controller board Usually OFF 9 amp 10 Freeze Timer 8 Control Board Check Usually OFF 7 ON for Models with Mechanical Bin Control OFF for Models with Thermostat 5 amp 6 Drain Counter 3 amp 4 Drain Timer 1 amp 2 Defrost Timer Switch Nos 9 and 10 Used for adjustment of freeze timer The freeze timer determines maximum freeze cycle time Upon termination of freeze timer machine initiates the harvest cycle After 2 consecutive timer terminations machine will shut down possibly indicating a problem a Defrost Control A thermistor semiconductor is used for a defrost control sensor The resistance varies depending on the suction line temperatures The thermistor detects the temperature of the evaporator outlet to start the defrost timer No adjustment is required If necessary check for resistance between thermistor leads and visually check the thermistor m
42. ounting located on the suction line next to the evaporator outlet Temperature C Resistance kQ 14 401 10 613 6 000 3 871 2 474 a 32 163 1 633 Check a thermistor for resistance by using the following procedures 1 Disconnect the connector K3 on the board 2 Remove the thermistor See V H Removal and Replacement of Thermistor 3 Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes 4 Check for a resistance between thermistor leads Normal reading is within 3 5 to 7 Replace the thermistor if it exceeds the normal reading b Defrost Timer No adjustment is required under normal use as the defrost timer is adjusted to the suitable position However if necessary because all the ice formed on the evaporator does not fall into the bin in the harvest cycle adjust the defrost timer to a longer setting by adjusting the dip switch No 1 amp 2 on the controller board Time seconds 5 80 ON OFF 90 23 c Drain Timer The drain timer is factory adjusted and no adjustment is required Dip Switch Setting T1 Time to drain the water tank T2 Time to restrain defrost completion d Drain Counter CAUTION Do not adjust the drain counter or the evaporator may freeze up The drain counter is factory adjusted to drain the water tank every 10 cycles and no adjustment is required Howeve
43. r where water quality is bad and the icemaker needs a pump drain more often the drain counter can be adjusted as shown in the table below Dip Ero Setting No 5 5 No 6 6 e Freeze Timer CAUTION Adjust to proper specification or the unit may not operate correctly The freeze timer is factory adjusted and no adjustment is required This setting determines the maximum allowed freeze time to prevent possible freeze up issues Dip Setting Time minutes No 9 No 10 10 Lor or eo 24 f Bin Control 1 Models with Thermostat CAUTION When the ambient temperature is below 7 C the bin control thermostat operates to stop the icemaker even if the ice storage bin is empty When the thermostat is set in the prohibited range the icemaker operates continuously even if the ice storage bin is filled with ice Setting in the prohibited range might cause severe damage to the icemaker resulting in failure No adjustment is required under normal use as the bin control is factory adjusted Adjust it if necessary so that the icemaker stops automatically within 10 seconds after ice contacts the bin control thermostat bulb 2 Models with Mechanical Bin Control CAUTION Dip switch no 7 must be set to the ON position If no 7 is set to the OFF position the machine will run continuously causing a freeze up condition No adjustment is required The bin control is factory adjusted 5 C
44. rks FOR THE EUROPEAN MARKET ICE CAPACITY Ibs day kg day SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 220 240 50 1 5 5 5 Min Freeze 104 F WT 80 F 15A MAXIMUM FUSE SIZE 15A WATER TEMP F 70 50 Oe E 480 218 446 202 403 183 454 206 402 182 360 163 446 202 365 166 321 146 438 199 355 161 281 127 10 10 C 21 15 C 30 25 C 540 245 471 214 355 161 Crescent Cube 9 5 Ibs 4 3 kg 480 pcs N A 90 70 F 70 50 F 1019 6 7 940 4 7 149 40 8 242 50 5 22 x 27 3 8 x 30 5 16 560 x 695 x 770 mm Stainless Steel Galvanized Steel Rear Net 146 Ibs 66 kg Shipping 170 Ibs 77 kg Cord Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Pipe Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N
45. rost cycle is completed b Defrost Timer The defrost cycle starts when the float switch opens and completes the freeze cycle But the defrost timer does not start counting until the thermistor senses 9 C at the evaporator outlet The period from the end of the freeze cycle up to the point of the thermistor s sensing varies depending on the ambient and water temperatures 14 c High Temperature Safety 53 4 C The temperature of the suction line in the refrigerant circuit is limited by the high temperature safety During the defrost cycle the evaporator temperature rises The thermistor senses 9 C and starts the defrost timer After the defrost timer counts down to zero the normal freeze cycle begins If the evaporator temperature continues to rise the thermistor will sense the rise in temperature and at 53 4 C the thermistor operates the high temperature safety This high temperature safety shuts down the circuit and the icemaker automatically stops This high temperature safety protects the unit from excessive temperature To reset the safety turn the power off and back on again This high temperature safety protects the unit from excessive temperature The control board will beep every 3 seconds The white reset button on the control board must be pressed with power on to reset the safety d Low Water Safety If the pump motor is operated without water the mechanical seal can fail To prevent this type of failure the control
46. rse order of which they were removed 7 Replace the panels in their correct positions 8 Plug in the icemaker Turn on the power supply N Removal and Replacement of Transformer 1 Turn off the power supply Unplug the icemaker 2 Remove the panels 3 Remove the closed end connectors from the transformer leads 4 Remove the transformer cover 5 Remove the transformer 6 Install the new transformer 7 Replace the transformer cover 8 Install new closed end connectors 9 Refit the panels 10 Plug in the icemaker Turn on the power supply 58 VI Cleaning and Maintenance Instructions IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment A Preparing the Icemaker for Long Storage WARNING When shutting off the icemaker for an extended time drain out all water from the water tank and remove the ice from the storage bin The storage bin should be cleaned and dried Drain the icemaker to prevent damage to the water supply line at sub freezing temperatures using air or carbon dioxide Shut off the icemaker until the proper ambient temperature is resumed Note When the icemaker is not used for two or three days it is sufficient to only move the control switch to the OFF position unless the icemaker will be at sub freezing temperatures 1 Remove the front panel 2 Move the control switch on the control box to the
47. t on the thermistor holder and the suction pipe 7 Wipe off moisture or condensation on the suction pipe 8 Smoothly apply recommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the thermistor holder concave 9 Attach the new thermistor to the suction pipe very carefully to prevent damage to the leads Secure it using the thermistor holder and recommended foam insulation 10 Secure the insulation using the plastic cable ties 11 Connect the thermistor leads through the bushing of the control box to the K3 connector on the controller board Note Do not cut the leads of the thermistor while installing it 12 Replace the control box cover and the panels in their correct positions 13 Plug in the icemaker Turn on the power supply 54 I Removal and Replacement of Fan Motor Note When replacing a fan motor with defective winding it is recommended that a new capacitor be installed 1 Turn off the power supply Unplug the icemaker 2 Remove the panels 3 Remove the closed end connectors from the fan motor leads 4 Remove the fan motor bracket and fan motor 5 Install the new fan motor and replace the removed parts in the reverse order of which they were removed 6 Replace the panels in their correct positions 7 Plug in the icemaker Turn on the power supply 55 J Removal and Replacement of Water Valve 1 Turn off the power supply Unplug the icemaker 2 Close the water supply line shut
48. t position 16 Move the control switch to the ICE position 17 Refit the front panel in its correct position 18 Turn on the power supply to fill the water tank with water 19 Turn off the power supply after 3 minutes 20 Remove the front panel 21 Move the control switch to the WASH position 22 Refit the front panel in its correct position 23 Turn on the power supply to rinse off the cleaning solution 24 Turn off the power supply after 5 minutes 25 Remove the front panel 26 Drain the water tank by removing one end of the pump tubing See Fig 5 27 Refit the pump tubing in its correct position 28 Repeat the above steps 16 through 27 three more times to rinse thoroughly Note Sanitizing should always be completed after cleaning or alternatively as an individual procedure if conditions exist to make it necessary If you do not sanitize the icemaker go to step 11 2 Sanitizing Procedure 61 2 Sanitizing Procedure Following Cleaning Procedure 1 Mix 3 gallons 11 41 of water and 1 5 fl 44 4 ml of a 5 25 sodium hypochlorite solution chlorine bleach 2 Complete steps 2 through 7 as detailed in 1 Cleaning Procedure 3 Pour the sanitizing solution into the water tank 4 Replace the insulation panel and the front panel in their correct positions Note Make sure that the control switch is in the WASH position 5 Turn on the power supply and start the sanit
49. te Fil Cycle XC DNO Harvest Cycle 1 4 and 2 3010 35 minutes Reverse Pump Out 1 3 and 2 LED 1 Comp LED 2 HGV CFM LED 3 LED 4 WY The built in safeties shut down the unit and have alarms as follows phi Type of Alarm Notes em 3 sec High Evaporator Temp Check for defrost problem stuck HGV or temperature 53 C relay hot water entering unit stuck headmaster or shorted thermistor Defrost Backup Timer gt Orange LED marked 20 MIN lights up defrost gt 20 min Check for open thermistor HGV not opening TXV leaking by low charge or inefficient compressor 3 Freeze Backup Timer Yellow LED marked 60 MIN lights up freeze gt 60 min Check for F S stuck closed up WV leaking by HGV leaking by TXV not feeding properly low charge or inefficient compressor Short Circuit Short circuit between the K4 connection machines with on the control board and the bin control mechanical bin control relay Check connections and replace ONLY wire harness if necessary Open Circuit Open circuit between the K4 connection machines with on the control board and the bin control mechanical bin control relay Check connections and replace ONLY wire harness if necessary To manually reset the above safeties press the white alarm reset button with the power supply on 92Vac orless 7 High Voltage Red LED will turn off if voltage protection control voltage operates
50. trogen gas flowing at a pressure of 3 to 4 psig 21 to 28 bar 8 Install the new drier 9 Check for leaks using nitrogen gas at 140 psig 9 65 bar and soap bubbles 10 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge See V A 2 Evacuation and Recharge R 404A 11 Replace the removed parts in the reverse order of which they were removed 12 Replace the top and front insulation and the panels in their correct positions 13 Plug in the icemaker Turn on the power supply 53 H Removal and Replacement of Thermistor CAUTION Fragile handle very carefully Always use a recommended sealant high thermal conductive type Model KE4560RTV manufactured by Shinetsu Silicone Part Code 60Y000 11 or Part Code 4A0683 01 or equivalent Always use a recommended foam insulation non absorbent type or equivalent Do not shorten or cut the thermistor leads when installing it 1 Turn off the power supply Unplug the icemaker Thermistor Lead Cable Tie 2 Remove the panels m m AZ ine ele AVA 22220 vu 3 Remove the control box cover lt gt 4 Disconnect the thermistor leads from the K3 connector on the controller board 5 Remove the plastic cable ties foam Foam Insulation Thermistor Holder insulation thermistor holder and thermistor See Fig 1 Fig 1 6 Scrape away the old sealan
51. trol during the first 5 minutes of the freeze cycle 1 If ice pushes the lever to the right after the first five minutes of the freeze cycle the controller board will allow the machine to complete the freeze cycle and the following harvest cycle before shutting down the machine This will prevent incomplete batches of ice from forming on the evaporator 3 Troubleshooting Mechanical Bin Control Only a Machine will not start 1 Move dip switch No 7 to the OFF position If the machine starts up within a few seconds the bin control is the likely problem If the machine does not start up refer to Section IV Service Diagnosis to verify that non bin control related issues are resolved 2 Check to make sure shipping tape has been removed and the wires are connected properly 3 Check to make sure no obstruction prevents the lever from moving to the bin empty position b Machine will not shut off 1 Refer to Section IV Service Diagnosis to verify that non bin control related issues are resolved 2 Dip switch No 7 should be in the on position If the switch is in the off position the controller board will not receive input from the bin control 3 Move the lever to the far right a If the machine does not shut off check the resistance values of the resistor wire harness You should read approximately 15 8 KQ between the black terminal and the red terminal that connect to the K4 connector on the co
52. turned OFF pressure switch is OFF thermistor temperature exceeds t1 or bin control is in full position To freeze cycle From freeze cycle Too Low Temp NN o No Defrost include drain 1 Thermistor Temperature 2 Float Switch OF ti t2 t3 N F N ng in 3 Compressor Control Switch 4 Pump Motor Dra ON 5 Fan Motor OFF ON Water Valve 3 1 OFF 1 Mechanical Bin Control Only The bin control will only shut off the ice machine during the first five minutes of the freeze cycle 2 The pump motor waits for 2 seconds before starting a drain cycle See 1 4 Controls and Adjustments 3 The icemaker does not complete a defrost cycle in the first 2 or minutes See 1 4 Controls and Adjustments 37 D Performance Data 1 KM 280MAH E APPROXIMATE ICE PRODUCTION PER 24 HR AMBIENT TEMP WATER TEMP F C F C 50 10 70 21 90 32 70 21 258 11 3 80 27 237 90 32 231 Ibs day kg day 100 38 229 APPROXMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day m day 100 38 FREEZING CYCLE TIME 70 24 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 TOTAL HEAT OF R
53. ut of position or loose 1 See V H Removal and attachment Replacement of Thermistor 9 Controller Board 1 Defrost timer is set too 1 Adjust longer referring to 4 Controls and Adjustments b Defrost Timer the Controller Board a Spray Tubes b Water lb Water System 1 1 Clean Refrigerant Undercharged Check for leaks and net d Expansion Valve 1 Bulb out of position or Place in position 2 2 Defective 2 2 Replace Hot Gas Solenoid i E MI winding opened Valve 2 Plunger does not move 2 Replace 3 Wiring to hot gas valve 3 Check for loose connection or open and replace f Water Supply Line 1 Too small requires 3 8 1 Increase water line OD line dedicated per size machine 9 Water Filter if 1 Flow rate too small 1 Replace with filter that installed has larger flow rate 45 C Low Ice Production 1 Freeze cycle time is a See chart A 3 and check high pressure controller i long b See chart B 1 and check float switch water solenoid valve and controller board 2 Harvest cycle time is a See chart B 2 and check evaporator water supply line water filter system water solenoid valve ambient and or water temperature thermistor and controller board D Abnormal Ice a Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin b See chart A 5 and check water supply lin
54. w drier 8 Check for leaks using nitrogen gas at 140 psig 9 65 bar and soap bubbles 9 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge See V A 2 Evacuation and Recharge R 404A 10 Attach the bulb to the suction line in position Be sure to secure it with clamps and to insulate it 11 Place the new set of expansion valve covers in position 12 Replace the panels in their correct position 13 Plug in the icemaker Turn on the power supply 51 F Removal and Replacement of Hot Gas Valve CAUTION Always use a copper tube of the same diameter and length when replacing the hot gas lines otherwise performance may be reduced IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Turn off the power supply Unplug the icemaker 2 Remove the panels 3 Recover the refrigerant and store it in an approved container See V A 1 Refrigerant Recovery 4 Remove the screw and the solenoid 5 Disconnect the hot gas valve or line valve using brazing equipment 6 Install the new valve with nitrogen gas flowing at a pressure of 3 to 4 psig 21 to 28 bar WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 121 C 7 Instal
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