Service Manual
Contents
1. NO 330 330 330 NO NO 440 NO 440 440 HYWLO9L WII OL ON 6 ON 8 ON L ON 9 ON G ON 7 ON E ON Z ON L ON 1300W ONILLAS HILIMS did 019 ya 48 M M om eum 00007 1 M E 108150 0000 M M M M M M M y i oun ASLLI AS OL t ISYIYNYYJ il ndino JeuuojsueuL A A NS x HI YISNIONOO E 102 To ad Wi Ex 40 Y zo 31M 0 Uu QD JAVA MVA a 3018 S 9 10H A d My mni m M as UE Y 1 i uu Q7 k ya co o Oo oi ct o e ne ux LARI di was Lo 0 ya ya T 0 i R k 21 T ES 018 m ANI 20 we OL Hf E mz k m l he ron Tm 7 0 10 0777 fo IN NM Umi iue CO 990 21 TA 0 iH See YOLOVINOD 21 L3NDVM etm ai ow mu in 015 NU HT dung E 43110410 T 4 E NT 1445 Tm N yg ul ng a ee d 1 no n Y0 1011109 111 d N 1811 et 3 A611 803 KLIM 1 09 0 2 802 mn Doo gt k N N y NId 0 9 n f VIO 48 09 341M 23 2 KM 1601MRH3 NO2. 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 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 em G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 24 900 BTU h AT 90 F 32 C WT 70 F 21 C TOTAL HEAT OF REJECTION FROM COMPRESSOR 3 200 BTU h AT 90 F 32 C WT 70 F 21 C CONDENSER VOLUME 441 CU IN URC 21F Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 27 4 KM 1601MRH3 with URC 22F APPROXIMATE ICE AMBIENT TEMP WATER TEMP F C PRODUCTION PER 24 HR F C 50 10 70 21 90 32 Ibs day _kg day 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 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 FROM CONDENSER 24 300 BTU h AT 90 F 32 C WT 70
3. b Icemaker and Bin 1 Drains not run 1 Separate the drain lines separately c Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin 41 V Replacement of Components A WARNING 1 This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death electric shock serious injury or fire 2 Move the control switch to the OFF position and turn off the power supply before servicing Lockout Tagout to prevent the power from being turned back on inadvertently CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after the unit is serviced Make sure that none have fallen into the storage bin Make sure all food zones in the icemaker and storage bin are clean after the unit is serviced For cleaning procedures see VI Cleaning and Maintenance Instructions A Service for Refrigerant Lines A WARNING 1 Repairs requiring the refrigeration circuit to be opened must be performed by properly trained and EPA certified service personnel 2 Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with
4. 42 A e WE 43 3 Evacuation and Recharge D A04A sss eene 43 B Important Notes for Component Heplacement 45 VI Cleaning and Maintenance Instructions AEN 46 A Cleaning and Sanitizing Procedures unn 46 1 Cleaning Probe QUE rc 47 2 Sanitizing Procedure Following Cleaning 48 15 46 2712 ANOS a ERREUR 49 C Preparing the Icemaker for Long Storage essere 49 Important Safety Information Throughout this manual notices appear to bring your attention to situations which could result in death serious injury or damage to the unit A WARNING Indicates a hazardous situation which could result in death or serious injury CAUTION Indicates a situation which could result in damage to the unit IMPORTANT Indicates important information about the use and care of the unit A WARNING This icemaker should be destined only to the use for which it has been expressly conceived Any other use should be considered improper and therefore dangerous The manufacturer cannot be held responsible for injury or damage resulting from improper incorrect and unreasonable use To reduce the risk of death electric shock serious injury or fire follow basic precautions including the following Only qualified service technicians should install service and maintain the icemaker Electrical connection must be hard wired and must meet national state and local electrical code requi
5. 5 Check for continuity and replace e High Pressure Control 1 Bad contacts 1 Check for continuity and replace 2 Dirty air filter or 2 Clean condenser 3 Ambient or condenser 3 Reduce temperature water temperature too warm 4 Refrigerant 4 Recharge overcharged 5 Fan not operating 5 See chart 1 6 6 Refrigerant line or 6 Clean and replace drier components plugged 36 1 The icemaker will not start continued 2 Water continues to be supplied and the icemaker will not start f Transformer 1 Coil winding opened 11 Replace or shorted 9 Wiring to Control Board 1 Loose connections or 1 Check for continuity and open replace h Thermistor 1 Leads shorted or 1 See I1 C 3 Controls and opened and high Adjustments b Harvest temperature or harvest Timer backup timer safety operates 1 beep or 2 beep alarm i Hot Gas Valve 1 Continues to open 1 Check for hot gas valve in freeze cycle and stuck open and replace freeze timer safety operates 3 beep alarm j Water Supply Line 1 Water supply off and 1 Check and get water supply cycle recommended pressure does not finish 2 Condenser water 2 Check and get pressure too low recommended pressure or off and pressure control opens and closes frequently to finally operate high temperature safety 1 beep alarm k Inlet Water Valve 1 Mesh filter or orifice 11 Clean gets clogged and water supply cycle d
6. board setting pump out occurs every cycle or every 2nd 5th or 10th cycle dip switch 5 amp 6 e Normal Harvest Cycle LEDs 1 4 and 2 are on Comp and FMR continue to run HGV remains open and WV opens As the evaporator warms the thermistor reaches 48 F 9 C The control board then receives the thermistor s 3 9 kQ signal and starts the harvest timer The water valve is open during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter When the harvest timer completes its count down the harvest cycle is complete and the next freeze cycle starts The unit continues to cycle through 3 4 and 5 sequence until the bin control senses ice and shuts the unit down Legend Comp compressor FMR remote fan motor FMS self contained fan motor F S float switch HGV hot gas valve LLV Liquid Line Valve PM pump motor WV inlet water valve 14 Jojow duund Wd uo1Ms IEOU S 4 JOJOW Ue e10UJ8J YIN 192M JOU AM OALA se 10 ADH JOJOW Ue peurejuoo JIes SIN 1OSSaIdUIO9 dwog pueba7 III e3nuruu 01 sulmjal aj9 o pue sdois 10sseJduuoo uedo si S J 1I 2 SNA pazib1aua ASH uedo S 4 3 s nunuo HW pezi amp ieue SIN s nunuo dwog 2 Wd sejoKo 2 AM SHES oun 1S AHEH senunuoo AM OL 40 g Z 1 uoee oes S 4 01 490 pezi amp ieue ep ADH ss l 10 UN 6 pezi amp ieue ya 4900 5 4 OZ OL 40 Ses1e eJ UY
7. 330 330 240 NO NO 330 NO 330 340 1 9 OL ON 6 ON H ON L ON 9 ON S ON 7 ON E 0 Z ON ON 1300H bi yg NILLIS HILIMS did 46 M sosa 29997 1 1 1 1 1 k E 108100 C0004 N N N N N N 171014 y y 38 3 NASLLI AS OL t P Nid d indino 1euuoJsueJ A JONYYO 0 D uni Lui 19 AS 5 E H Ho INV END 1078 Uu 100 m E wou 48 FE NS HIE D to Wi o mis m a 77 G 3 WYA d BU Gu wl 3009 4070 341M S ll al Fo MS ASH 1041 d Masa ji to 1 ye tO ol M 1807 MOEZ Jo j SN o NIYA H nga 0 Jo 88 yay 100 alla TT i S m Ns al ya be 7 301701 m m 1 m 2 ren anal i 10 N ya E lo 440 O ya 3 o oJ 0o O NS 1014 7 ya 1 me 1 1M 22 you y E wl O en mw simi Y0LJVINOJ JILINDYN WE DR m T m en 4 vo 3804 308180 NIG 9 ya y ya ji E 11 H 9194 21 42128 0194 2 2017 ul IND no n2 YOUMS 9INSSIIG UBIH E 09 0 2 802 24 C Performance Data 1 KM 1601MRH with URC 21F APPROXIMATE ICE AMBIENT TEMP WATER TEMP F C PRODUCTION PER 24 HR F C 50 10 70 21 90 32 Ibs day _kg day 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 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 em G
8. N Line Valve Receiver Capacitor Box KM 1601MRH N Transformer Box NN we DUNA gt 7 Y Sf y 7 Wi Cleaning Valve Control Box Bin Control Thermostat Float Switch Water Pump KM 1601MRH3 Drier Compressor 11 2 URC 21F URC 22F Fan Blade Condenser Fan Motors Condenser Fan Blade Headmaster C P R V Junction Box Discharge Line Liquid Line Comnection Connection ies B Sequence of Operation 1 Sequence Cycles and Shutdown The steps in the sequence are as outlined below When power is supplied a 5 second delay occurs at startup Note that the order of the LEDs from the outer edge of the control board is 1 4 3 2 a One Minute Fill Cycle LED 4 is on WV opens and the fill period begins After 1 minute the control board checks for a closed F S If F S is closed the harvest cycle begins If not WV will remain energized through additional 1 minute cycles until water enters the sump and F S closes This serves as a low water safety to protect the water pump b Initial Harvest Cycle LEDs 1 4 and 2 are on WV remains open Comp and FMR energize HGV opens and harvest begins As the evaporator warms the thermistor located on the suction line checks for a 48 F 9 C temperature When 48 F 9 C is reached a 3 9 kQ signal turns the harvest
9. 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 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 condenser unit C Preparing the Icemaker for Long Storage A 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 subfreezing 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 subfreezing temperatures 1 Remove the water from the potable water supply line 1 Remove the front panel 2 Move the control switch on the control box to the OFF position 3 Wait 3 minutes 4 Close the potable water supply line shut off valve and open the potable water supply line drain valve 5 Allow the line to drain by gra
10. control board to the components slide the control board K1 ten pin connector out far enough to allow multimeter lead contact With the unit in the cycle to be tested check output voltage from the corresponding pin on the control board K1 ten pin connector to ground If output voltage is not found and the appropriate LED is on the control board is bad and should be replaced 31 C Bin Control Check To check the thermostatic bin control follow the steps below CAUTION When the ambient temperature is below 45 F 7 C the thermostatic bin control switch opens and shuts down 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 may result in severe damage to the icemaker The thermostatic bin control is factory set and generally no adjustment is required However adjustment may be needed in some conditions particularly at higher altitude locations Note that when the thermostatic bin control switch is open the control board red POWER OK LED is off 1 Turn off the power supply 2 Remove the front panel then move the control switch to the OFF position 3 Clear any ice away from the thermostatic bin control bulb 4 Remove the control box cover then disconnect the thermostatic bin control wires from the thermostatic bin control switch 5 Hold your hand aro
11. electronic devices on the control board or the back of the control board Do not change wiring and connections Do not misconnect K3 K4 and K5 because the same connector is used for the thermistor and float switch K4 is not connected 5 Always replace the whole control board assembly if it goes bad 6 Do not short out power supply to test for voltage 1 Control Board Layout E Control Board Output Test Switch used to test relays on control Alarm Reset Switch Dip Switch board OUTPUT TEST ea 0008810 Backup Freeze Timer LED RB RS Connector K3 t a BS Ls o n He Harvest Control R30 020 610 010 60 20 50 exe mL bio Contro B 0 thermistor sli B Backup Harvest 7557 A EA o SIE Q Connector K4 Timer LED o 257 SSC not connected m m R16 Alarm Buzzer Power LED lights when Microprocessor power is supplied control board to the control 22 revision level board oa indicated by last 2 So digits on label Relay LEDs 4 indicate which relays are energized as listed below Connector K5 Float Switch Part
12. equivalent are recommended Secure the thermistor with the holder then insulate it Be very careful to prevent damage to the leads 45 VI Cleaning and Maintenance Instructions A Cleaning and Sanitizing Procedures A WARNING Ensure all components fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment A WARNING 1 Hoshizaki recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water conditions 2 To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners 3 Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin CAUTION 1 The cleaning valve is used to allow solution flow to the inside of the evaporator during the cleaning and sanitizing operation It should be closed for all icemaking operation The compressor will not operate unless this valve is completely closed 2 To open the cleaning valve the valve handle should be parallel to the valve body To close the valve the valve handle should be at a right angle to the valve body CLOSED POSITION OPEN POSITION 46 1 Cleaning Procedure 1 Dilute 27 fl oz 800 ml of Hoshizaki Scale Away with 5 gal 19 1 of warm water 2 Remove all ice from the evaporator and the storage bin Note To remove cubes on the evaporator turn off the power s
13. full follow the steps in IV D 2 Float Switch Cleaning After cleaning the float switch check it again Replace if necessary 33 2 Float Switch Cleaning Depending on local water conditions scale may build up on the float switch Scale on the switch can cause the float to stick In this case the float switch should be cleaned 1 Turn off the power supply 2 Remove the front panel then move the control switch to the OFF position 3 Remove the insulation panel then remove the drain plug located on the lower front part of the ice chute See Fig 1 Allow the water tank to drain 4 Replace the drain plug in its correct position Be careful not to cross thread it 5 Disconnect the vent tube and the flush tube from the top of the float switch then remove the float switch assembly from the mounting bracket and remove the rubber boot from the bottom of the float switch assembly See Fig 2 6 Remove the retainer rod from the bottom of the float switch assembly then remove the float Be careful not to bend the retainer rod excessively when removing it 7 Wipe down the float switch assembly s housing shaft float and retainer rod with a mixture of 1 part Hoshizaki Scale Away and 25 parts warm water Clean the inside of the rubber boot and hose with cleaning solution Rinse the parts thoroughly with clean water 8 Reassemble the float switch assembly and replace it and the rubber boot in their correct positions Reconne
14. or liquid dispensing device to add the remaining liquid charge through the low side access valve with the unit running 9 Close the high and low side gauge manifold valves then disconnect the gauge manifold hoses 10 Cap the access valves to prevent a possible leak 44 B Important Notes for Component Replacement CAUTION When replacing a component listed below see the notes to help ensure proper operation Component 1858 wees AA Compressor Install a new start capacitor run capacitor and start relay Expansion Valve l Attach the expansion valve bulb to the suction line in the same location as the previous bulb The bulb should be between the 10 and 2 o clock positions on the tube Secure the bulb with the clamp and holder then insulate it Hot Gas Valve l Replace the strainer when replacing the hot gas valve Liquid Line Valve Use copper tube of the same diameter and length when replacing valve lines Fan Motor Install a new capacitor Pump Motor Install a new capacitor Thermistor Attach the new thermistor to the suction line in the same location as the previous thermistor The thermistor should be at the 12 o clock position on the tube e Smoothly fill the recessed area of the thermistor holder with high thermal conductive type sealant Hoshizaki America part number 4A0683 01 Silicone Heat Sink Compound 10 8108 manufactured by GC Electronics KE 4560 RTV manufactured by ShinEtsu Silicones or
15. over to the adjustable harvest timer which is factory set for normal conditions The timer has settings of 60 90 120 and 180 seconds dip switch 1 amp 2 The water valve is open during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter When the harvest timer completes its count down the harvest cycle is complete and the freeze cycle starts The minimum total time allowed by the control board for a complete harvest cycle is 2 minutes c Freeze Cycle LED 1 is on Comp and FMR continue to run PM and FMS energize LLV opens HGV and WV close and the freeze cycle starts For the first 5 minutes the control board will not accept a signal from F S This 5 minute minimum freeze acts as a short cycle protection At the end of 5 minutes F S assumes control As ice builds on the evaporator the water level in the sump lowers The freeze continues until F S opens and terminates ice production d Pump Out Cycle LEDs 1 3 and 2 are on Comp and FMR continue to run HGV opens LLV closes and FMS deenergizes PM stops for 2 seconds and reverses taking water from the bottom of the sump and forcing pressure against the check valve seat allowing water to go through the check valve and down the drain At the same time water flows through the small tube to power flush the F S When the pump out timer stops counting the pump out is complete Pump out always occurs on the 2nd harvest after startup Then depending on the control
16. pressurized air for leak testing CAUTION Do not leave the system open for longer than 15 minutes when replacing or servicing parts 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 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 Install the new drier with the arrow on the drier in the direction of the refrigerant flow When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 1 Refrigerant Recovery The icemaker is provided with refrigerant access valves Using proper refrigerant practices recover the refrigerant from the service valves and store it in an approved container Do not discharge the refrigerant into the atmosphere 42 2 Brazing A WARNING 1 R 404A itself is not flammable at atmospheric pressure and temperatures up to 176 F 80 C 2 R 404A itself is not explosive or poisonous However when exposed to high temperatures open flames R 404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous 3 Do not use silver alloy or copper alloy containing arsenic 4 Use an electronic leak detector or soap bubbles to check for leaks Add
17. pue Daum uonejedo senunuoo YING 9 6 4 87 seuoeei pezibieue ADH 08S Z 40 sdo s Jojow duing ezeal4 s nunuo dwog duer J0 sIuIey L peziBieue duo y peziBieu3 AM Aey p puooes q aney IM preoq jo41u09 I 4 p so 9 4 lt oguoo 041009 UI usi gt Jeun amu G gt peso S 4 ajay sulb q sAemje dnes jelu 101 U09 yx 013u09 ul Jeun ejnuiu oj Ul Jojsiuueu gt um s sawn ezeeJj oun 2 WNWIXEN sejnuiui OZ SUD 19 WNWIXEN e r o 114 mo dund Tl s mnulul G oU 92991 WNWIUIN e s Mulu 9 3UIN A PA J93eM WINUIXENN e ejnuiy SUO L L 2 lt lt sdajs 3949 1 2 15 Z 422 41 2 1091 322 0 412 2 1091 yeys MOL peog 011402 3 2 Sequence Flow Chart 18 C Control Board A Hoshizaki exclusive solid state control is employed in KM 1601MRH and KM 1601MRH3 Modular Crescent Cubers All models are pretested and factory adjusted CAUTION 1 The control board is fragile handle very carefully 2 The control board contains integrated circuits which are susceptible to failure due to static discharge It is especially important to touch the metal part of the unit when handling or replacing the control board Do not touch the
18. refrigeration check valve and compressor 2 Harvest cycle time is a See chart 2 2 and check control board thermistor evaporator ambient and or water temperature water supply line inlet water valve line valve and gas valve 40 4 Abnormal Ice Possible Cause 1 Small cubes a Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin b See chart 1 5 and check water supply line inlet water valve water system pump motor and control board 2 Cloudy or irregular a See chart 2 1 and 2 3 and check float switch inlet water valve control board cubes spray tubes water system refrigerant charge and expansion valve b Spray Guide c Water Quality 1 High hardness or 1 Install a water softener or contains impurities filter 5 Other Possible Cause 1 icemaker will not stop a Bin Control Thermostat 1 Set too cold 1 Adjust warmer when bin is filled with ice 2 Defective 2 Replace 2 Abnormal noise a Pump Motor 1 Bearings worn out 1 Replace b Fan Motor 1 Bearings worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade 3 Fan blade does not 3 Replace move freely c Compressor 1 Bearings worn out or 1 Replace cylinder valve broken 2 Mounting pad out of 2 Reinstall position d Refrigerant Lines 1 Rub or touch other 1 Replace lines or surfaces 3 Ice in storage bin a Drain Line s 1 Plugged often melts
19. the storage bin area If no ice is near the thermostatic bin control bulb or the red POWER OK LED does not come on even after clearing away ice check the thermostatic bin control See IV C Bin Control Check If the thermostatic bin control is okay closed and the red POWER OK LED is off check the fuse control switch contacts high pressure switch and control transformer secondary circuit Transformer output is 10 5V at 115V primary input If the secondary circuit has proper voltage and the red LED is off the control board is bad and should be replaced If the secondary circuit does not have proper voltage check the control transformer primary circuit Check for 115V at the control board K1 ten pin connector Check the 10 pin BR wire to a white neutral wire for 115V Always choose a white neutral wire to establish a good neutral connection when checking voltages For additional checks see IV F 1 No Ice Production 3 The OUTPUT TEST button provides a relay sequence test Make sure the control switch is in the ICE position then press the OUTPUT TEST button The correct lighting sequence is 2 3 4 1 Note that the order of the LEDs from the outer edge of the control board is 1 4 3 2 Components e g compressor will cycle during the test Following the test the icemaker resumes operation If the LEDs do not light as described above the control board is bad and should be replaced 4 To verify voltage output from the
20. 0A WATER TEMP F 50 70 90 1486 674 1458 661 1366 620 1465 664 1422 645 1300 590 1458 661 1391 631 1280 581 1422 645 1365 619 1178 534 Crescent Cube 28 3 lbs 12 8 kg 1440 pcs N A 90 70 F 70 50 F 2640 4 55 2460 3 97 267 19 2 498 33 5 2 YES 30 x 27 4 x 41 7 762 x 695 x 1059 mm Stainless Steel Galvanized Steel Rear Net 259 Ibs 117 kg Shipping 316 lbs 143 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Tube Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model CS18K6E TF5 Air Cooled Remote Condenser Unit URC 22F Vertical type Stainless Steel and Copper Thermostatic Expansion Valve Condensing Pressure Regulator on URC 22F R 404A 22 lb 4 3 oz 10 100g Icemaker 14 Ibs 8 8 oz Cond Unit 7 Ib 11 5 oz High 467PSIG Low 230PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Dispenser or Ice Storage Bin Remote Condenser Unit VOLTAGE RANGE 187 253 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 Condenser Unit 1 URC 21F URC 22F AC SUPPLY VOLTAGE FAN MOTOR EXTERIOR DIMENSIONS DIMENSIONS INCLUDING LEGS
21. 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 23 400 BTU h AT 90 F 32 C WT 70 F 21 C TOTAL HEAT OF REJECTION FROM COMPRESSOR 3 200 BTU h AT 90 F 32 C WT 70 F 21 C CONDENSER VOLUME 441 CU IN URC 21F Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 25 2 KM 1601MRH with URC 22F APPROXIMATE ICE AMBIENT TEMP aa ANE AES CFPC 70 21 677 667 0 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 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 FROM CONDENSER 27 400 BTU h AT 90 F 32 C WT 70 F 21 C TOTAL HEAT OF REJECTION FROM COMPRESSOR 3 200 BTU h AT 90 F 32 C WT 70 F 21 C CONDENSER VOLUME 214 CU IN Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 26 3 KM 1601MRH3 with URC 21F APPROXIMATE ICE AMBIENT TEMP FESTEN CFPC
22. 417 643 1346 610 100 1449 657 1400 635 1280 581 Crescent Cube 27 9 lbs 12 7 kg 1440 pcs N A 90 70 F 70 50 F 2740 4 64 2590 4 17 264 18 6 521 34 9 2 YES 30 x 27 4 x 41 7 762 x 695 x 1059 mm Stainless Steel Galvanized Steel Rear Net 259 165 117 kg Shipping 316 Ibs 143 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Tube Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model CS18K6E PFV Air Cooled Remote Condenser Unit URC 22F Vertical type Stainless Steel and Copper Thermostatic Expansion Valve Condensing Pressure Regulator on URC 22F R 404A 22 lb 4 3 oz 10 100g Icemaker 14 Ibs 8 8 oz Cond Unit 9 Ib 11 2 oz High 467PSIG Low 230PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Dispenser or Ice Storage Bin Remote Condenser Unit VOLTAGE RANGE 187 253 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 3 KM 1601MRH3 with URC 21F AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE S
23. EDs from the outer edge of the control board is 1 4 3 2 For more information see II B Sequence of Operation Time LEDs are On Sequence Step Energized 1 Minute Fill Cycle LES CREDO Wy 1 EEE 0 TEE Comp FMR Freeze Cycle Comp PM 15 minutes freeze timer 130 to 35 minutes FMR FMS setting LLV PM FMR The built in safeties shut down the unit and have alarms as follows 3 sec High Evaporator Temp Check for harvest problem stuck HGV or temperature gt 127 F relay hot vvater entering unit stuck HM 53 C or shorted thermistor Harvest Backup Timer Orange LED marked H TIMER lights up harvest gt 20 min for two Check for open thermistor HGV not cycles in a row opening TXV leaking by low charge or inefficient compressor Freeze Timer Yellow LED marked F TIMER lights up freeze gt specified setting Check for F S stuck closed up WV for two cycles in a row leaking by HGV leaking by TXV not Timer is factory set using feeding properly low charge HM not dip switches 9 8 10 bypassing or inefficient compressor To manually reset the above safeties press the alarm reset button with the power supply on Low Voltage Red LED will turn off if voltage protection 92Vac 5 or less operates a High Voltage The control voltage safeties automatically 147Vac 5 or more reset when voltage is corrected Legend Comp compressor FMR remote fan motor FMS self contained fan
24. EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC REFRIGERANT CONDENSER FAN MOTOR PROTECTION REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE OPERATING CONDITIONS ACCESSORIES SUPPLIED WxDxH WxDxH URC 21F URC 22F URC 21F URC 22F 115 60 1 Connection to Icemaker 115V Total 2 6FLA 130W 46 3 8 x 15 11 16 x 25 15 16 1178 x 398 x 659 mm 48 7 16 x 18 1 8 x 40 7 8 1230 x 460 x 1039 mm Galvanized Steel Net 158 Ibs 72 kg Shipping 169 Ibs 77 kg Net 134 Ibs 61 kg Shipping 145 Ibs 66 kg Permanent Connection Discharge Line 1 1 16 12 UNF Fitting 10 PARKER Liquid Line 5 8 18 UNF Fitting 6 PARKER Air cooled Fin and tube type Thermal Protection Condensing Pressure Regulator R 404A 9lb 110z 44009 R 404A 7lb 11 5 oz 35009 High 467 PSIG 32 2 Bar VOLTAGE RANGE 104 127 VAC AMBIENT TEMP 20 122 F Leg 2 pcs Hex Head Bolt w Washer 8 x 16 8 pcs Hex Nut 8 8 pcs Note We reserve the right to make changes in specifications and design without prior notice 10 II General Information A Construction 1 KM 1601MRH KM 1601MRH3 Water Supply Inlet o o gt c o c o o x UI Hot Gas Valve lt A Junction Box Inlet Water Valve ay de Spray Tube Evaporator AV NEC 8 NG N j NA FRI NX VAR AN mv MEN NNW D V LL 22 n 4 Vr ex le 1 D Ku
25. F 219C TOTAL HEAT OF REJECTION FROM COMPRESSOR 3 200 BTU h AT 90 F 329C WT 70 F 219C CONDENSER VOLUME 214 CU IN Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 28 IV Service Diagnosis A WARNING 1 This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death electric shock serious injury or fire Risk of electric shock Use extreme caution and exercise safe electrical practices Moving parts e g fan blade can crush and cut Keep hands clear CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after the unit is serviced Make sure that none have fallen into the storage bin Make sure all food zones in the icemaker and storage bin are clean after the unit is serviced For cleaning procedures see VI Cleaning and Maintenance Instructions A Diagnostic Procedure The diagnostic procedure is basically a sequence check which can be used at unit start up or for system diagnosis Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 70 F or warmer air and 50 F or warmer water temperatures Before conducting a 10 minute checkout check for correct
26. Hoshizaki America Inc Modular Crescent Cuber Models KM 1601 MRH 3 SERVICE MANUAL A Superior Degree of Reliability www hoshizaki com Number 73129 Issued 6 16 2006 Revised 3 28 201 I IMPORTANT Only qualified service technicians should install service and maintain the icemaker No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual Failure to service and maintain the equipment in accordance with this manual may adversely affect safety performance component life and warranty coverage Hoshizaki provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should the reader have any questions or concerns which have not been satisfactorily addressed please call write or send an e mail message to the Hoshizaki Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn Hoshizaki Technical Support Department Phone 1 800 233 1940 Technical Support 770 487 2331 Fax 1 800 843 1056 770 487 3360 E mail techsupport hoshizaki com Web Site www hoshizaki com NOTE To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem IMPORTANT This manual should be read carefully before t
27. Number B8 RI lo o o LED 2 vn 823 K1 Hot Gas Valve HGV Sitten R7 3 X3 esent es Pins 41 through 10 Self Contained Fan a e o o o m 1 9 Magnetic Contactor Motor FMS FMS 2 Hot Gas Valve AA 20 7 off when LED on jo o 0 43 Line Valve CH e olo olo LED 3 R pn 7777 Self Contained Fan Motor FMS Pump Motor PM SE bm 3 ete 4 Pump Motor icemaking on at pump out only Ee Sto SS kl 5 Pump Motor drain um elo 6 Water Valve LED 4 Y y p9 o o S 7 10 Power line bin control Water Valve WV En o SR EM x 2 8 Open 7 o Switch for C and Compressor Comp lt O ALPINE control board Remote Fan Motor o o service control boards only FMR e Transformer Connector Control Board Part Number 2A1410 01 factory 2A1410 02 service 17 2 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 control board conducts an internal timer check A short beep occurs when the power switch is turned OFF The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below Note that the order of the L
28. R desea lika ia 19 a Default Dip Switch 19 b Harvest Timer dip switch 1 amp 2 19 Pump Out Timer dip switch 3 84 ener zinaenea 20 d Pump Out Frequency Control dip switch 5 6 2 20 e Factory Use S4 dip switch 7 amp 8 22 20 f Freeze Timer dip switch 9 amp Diente 21 cr ris EE 21 III Technical Information as 22 A Water Circuit and Refrigeration sss 22 ES ETO 1 E 23 L PRT OTN si AP UU q 23 2 KM 1601MRH3 o S nanaan kiinaa inaina aana Naonna ia 24 C Performance Dal ee 25 1 KM 1601MRH with URC 21F es er ae 25 2 KM 1601MRH 0007777777 7 26 3 KM 1601MBRHS with URC 21 FF 27 NERT 28 IV Service DANOS PN 29 A Diagnostic Procedure Liu eniro aaa c od kc ideas 29 B Control Board Check cueca ii M eeeeiecoe 31 C Bin Control OC qe 32 D Float Switch Check and Cleaning seccion a 33 1 Float Switch Ch Kaina aikatae kiwa na PP E 33 PP A 34 E Thermistor Check susana aan eebe 35 a iL 36 1 No CE Produc ri tsa direitos 36 2 Evaporator is Frozen Up E 39 3 LOW lce I IU ON cannot atente 40 A Abnormal CE pO 41 Ao a 41 V Replacement of Components 552 42 A Service for Refrigerant Lines 42 1 Refrigerant
29. RC 21F R 404A 24 lb 4 0 oz 11 0009 Icemaker 14 Ibs 8 8 oz Cond Unit 9 Ib 11 2 oz High 467PSIG Low 230PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Dispenser or Ice Storage Bin Remote Condenser Unit VOLTAGE RANGE 187 253 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 4 KM 1601MRH3 with URC 22F AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks 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 CEC CEE TIER LEVEL ENERGY STAR 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 208 230 60 3 8 4A 5 Min Freeze AT 104 F WT 80 F 2
30. TORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W KVVH 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 208 230 60 3 8 4 A 5 Min Freeze AT 104 F WT 80 F 20A WATER TEMP F 70 90 50 1471 667 1448 657 1354 614 1453 659 1417 643 1290 585 90 1448 657 1392 631 1277 579 100 1408 639 1365 619 1171 531 Crescent Cube 28 0 Ibs 12 7 kg 1440 pcs N A 90 70 F 70 50 F 2640 4 6 2410 3 9 267 19 2 491 33 4 30 x 27 4 x 41 7 762 x 695 x 1059 mm Stainless Steel Galvanized Steel Rear Net 259 Ibs 117 kg Shipping 316 Ibs 143 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Tube Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model CS18K6E TF5 Air Cooled Remote Condenser Unit URC 21F Vertical type Stainless Steel and Copper Thermostatic Expansion Valve Condensing Pressure Regulator on U
31. a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 1 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG Note Because the pipes in the evaporator case are specially coated to resist corrosion it is important to make connections outside the evaporator case when possible If it is necessary to braze inside the evaporator case use sandpaper to remove the coating from the brazing connections before unbrazing the components CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 2 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 3 Evacuation and Recharge R 404A 1 Attach a vacuum pump to the system Be sure to connect the charging hoses to both high and low side ac
32. and turns operation of harvest over to the harvest timer The timer completes counting 1 to 3 minutes The unit then cycles to freeze Diagnosis Check if compressor is running hot gas valve is open water valve still open Average harvest cycle at factory setting is 2 to 3 minutes How long does initial harvest last 1 5 minutes after initial harvest begins touch the compressor discharge line Is it hot If not check refrigerant pressures and compressor operation If it is hot touch the inlet line to the evaporator Is it hot If it is hot and the freeze cycle is not starting check the harvest timer adjustment the thermistor for open circuit the discharge line temperature compressor efficiency and if the hot gas valve is fully open 5 Freeze Cycle compressor remains energized pump motor line valve on remote condenser unit and fan motor energize The inlet water valve and hot gas valve de energize The unit is held in freeze by a 5 minute short cycle protection timer After 5 minutes the freeze cycle operation is transferred to the float switch for freeze termination During the first 5 minutes of freeze confirm that the evaporator temperature drops After 7 minutes in freeze remove the black float switch lead from the K5 connector The unit should immediately switch to the pump out cycle Diagnosis If the evaporator is not cold check to see if the hot gas valve is still open or if the expansion valve is not opening properly if t
33. bs 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 208 230 60 1 3 wire with neutral for 115V 11 6 A 5 Min Freeze AT 104 F WT 80 F WATER TEMP F CF 90 1227 557 Crescent Cube 29 8 Ibs 13 5 kg 1440 pcs N A 90 70 F 70 50 F 2670 4 5 2450 3 9 263 18 5 483 32 0 30 x 27 4 x 41 7 762 x 695 x 1059 mm Stainless Steel Galvanized Steel Rear Net 259 Ibs 117 kg Shipping 316 Ibs 143 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Tube Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model CS18K6E PFV Air Cooled Remote Condenser Unit URC 21F Vertical type Stainless Steel and Copper Thermostatic Expansion Valve Condensing Pressure Regulator on URC 21F R 404A 24 Ib 4 0 oz 11 000g Icemaker 14 Ibs 8 8 oz Cond Unit 9 Ib 11 2 oz High 467PSIG Low 230PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto r
34. cess valves 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 Open the gauge manifold valves then open the high and low side access valves Never allow the oil in the vacuum pump to flow backwards 3 Allow the vacuum pump to pull down to a 29 9 Hg vacuum Evacuating period depends on pump capacity 43 4 Close the low side valve and high side valve on the gauge manifold 5 Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder Remember to loosen the connection and purge the air from the hose For refrigerant charge see the rating label inside the icemaker Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 latest edition be used 6 A liquid charge is required when charging an R 404A system to prevent fractionation Place the service cylinder on the scales if the service cylinder is not equipped with a dip tube invert the service cylinder then place it on the scales Open the high side valve on the gauge manifold 7 Allow the system to charge with liquid until the proper charge weight is met 8 If necessary add any remaining charge to the system through the low side CAUTION To prevent compressor damage use a throttling valve
35. ct the vent tube and the flush tube 9 Move the control switch to the ICE position 10 Replace the insulation panel and front panel in their correct positions 11 Turn on the power supply to start the automatic icemaking process D Flush Shaft Float Switch Housing Float Retainer Rod Rubber Boot and Hose Fig 2 34 E Thermistor Check To check thermistor resistance follow the steps below 1 Turn off the power supply 2 Remove the front panel then move the control switch to the OFF position 3 Remove the control box cover 4 Remove the thermistor 5 Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes 6 Disconnect the white thermistor connector from the control board WHITE K3 connector and check the resistance between thermistor leads Normal reading is within 4 7 to 6 2 kQ If outside the normal reading replace the thermistor See V B Important Notes for Component Replacement If inside the normal reading continue to the next step 7 Replace the thermistor in its correct position See V B Important Notes for Component Replacement 8 Recomnect the white thermistor connector to the control board WHITE K3 connector 9 Replace the control box cover in its correct position then turn on the power supply 10 Move the control switch to the ICE position 11 Once the harvest cycle star
36. eplace drier and trapped recharge b Compressor 1 Defective valve 1 Replace c Hot Gas Valve 1 Continues to open in 1 Check and replace freeze cycle d Line Valve 1 Continues to close in 1 Check and replace freeze cycle e Inlet Water Valve 1 Water valve is wide 1 Check for water leaks with open during freeze icemaker off f Headmaster C P R 1 Not operating properly 1 Replace headmaster Remote Unit and liquid line temperature too warm 2 Evaporator is Frozen Up Possible Cause 1 Freeze cycle time is a Float Switch 1 Leads short circuit or 1 Check and replace too long defective switch 2 Float does not move 2 Clean or replace freely Inlet Water Valve 1 Diaphragm does not 11 Check for water leaks with close icemaker off c Control Board 1 Defective 1 See IV B Control Board Check b b fall into bin in harvest cycle evaporator does not Water Supply Line 1 Water pressure too 11 Check and get low recommended pressure c Water Filter System 1 Dirty Restricted 1 Replace filter d Inlet Water Valve 1 Dirty mesh filter or 1 Clean orifice 2 Diaphragm does not 12 Check for water leaks with close icemaker off e Ambient and or water 1 Too cool 1 Increase temperature temperature f Line Valve 1 Continues to open in 1 Check operation in harvest harvest cycle cycle and replace Possible Cause 2 All ice formed on g Thermistor 1 Out o
37. eset High Pressure Control Switch Float Switch N A Ice Dispenser or Ice Storage Bin Remote Condenser Unit VOLTAGE RANGE 187 253 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 2 KM 1601MRH with URC 22F AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks 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 CEC CEE TIER LEVEL ENERGY STAR 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 w URC 22F DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 208 230 60 1 3 wire with neutral for 115V 11 6A 5 Min Freeze AT 104 F WT 80 F 20A 20A Ambient WATER TEMP F TempCF 50 70 090 70 1493 677 1471 667 1410 640 80 1476 670 1441 654 1364 619 90 1471 667 1
38. f position or 1 See V B Important ecaorator does not loose attachment Notes for Component fall into bin in harvest Replacement continued h Control Board 1 Harvest timer is set 11 Adjust longer referring too short to I1 C 3 Controls and Adjustments c Harvest Timer 2 Defective 2 See IV B Control Board Check 3 Other a Spray Tubes 1 Clogged 2 Out of position 2 Place in position GC 1 e 1 Check for leaks and recharge d Expansion Valve 1 Bulb out of position or 1 Place in position loose attachment 2 Replace e Hot Gas Valve 1 Coil winding opened 1 Replace 2 Plunger does not 2 Replace move 3 Wiring to hot gas 3 Check for loose valve connection or open and replace f Ice Cube Guide 1 Out of position and ice 1 Place in position trapped g Water Supply Line 1 Too small requires 1 Increase water line size 1 2 OD line dedicated per machine h Water Filter 1 Flow rate too small 1 Replace with filter that has larger flow rate 3 Low Ice Production Possible Cause 1 Freeze cycle time is a See chart 1 3 and check dirty air filter or condenser ambient or water long temperature water pressure condenser water regulating valve water cooled model and refrigerant charge b See chart 2 1 and check float switch inlet water valve and control board c Check pump hot gas valve headmaster C P R remote air cooled model expansion valve
39. he icemaker is serviced or maintenance operations are performed Only qualified service technicians should install service and maintain the icemaker Read the warnings contained in this booklet carefully as they give important information regarding safety Please retain this booklet for any further reference that may be necessary CONTENTS Important Safety Information endeten 5 E GE 6 A cemakef maa nandaan DN MEE 6 1 KM 1601MRH with ET e E 6 2 KM 1601MRH with URC 22F 7 3 KM 1601 MHH3 den a eR Ru ARR E 8 4 KM 1601MBRHS with URC 22F RAYA Phe PA nn anna xu EE EE 9 e P 10 IE General Informati n EE 11 an 11 1 KM 1601MRH KM 1601MRH3 cooco00000onin nanonanenancncncnnocononcninnannnanonananadanddebnnRanonis 11 A 12 B Sequence of Operation p Rm 13 1 Sequence Cycles and Shutdown cccccccnnonccccnccnnnnnccccnncncnnnannnnnnnnnnnnnannnnnnnnnnnnnnnnnnnos 13 a One Minute Fill Cycle T 13 b Initial Harvest Cycle T 13 c Freeze Cycle Mm 13 O Mm 13 e Normal Harvest Cycle kumuuzia ununuzi 14 2 Seguence Flow COMA EE 15 C Control 30 s o 16 1 Control Board Layout aa c aaa tdi 17 2 LED Lights and Audible Alarm Safeties AAA 18 3 Controls and Ad USl mili scene raten tum L
40. he water valve is continuing to fill the reservoir if there are improper unit pressures an inoperative compressor or an inoperative headmaster C P R remote condenser unit only If the unit remains in freeze with the float switch removed replace the control board Note Normal freeze cycle will last 20 to 40 minutes depending on model and conditions Cycle times and pressures should follow performance data provided in this manual 6 Pump Out Cycle 10 20 second pump out the compressor remains energized the hot gas valve energizes the fan motor de energizes the pump motor stops for 2 seconds and starts in reverse rotation for 10 20 seconds This removes contaminants from the water reservoir through the check valve drain valve and down the drain and allows for a power flush of the float switch Check for clear tubing at the check valve housing and check the unit drain for water flow Diagnosis If the pump motor does not reverse check the circuit and capacitor If water does not pump out remove the check valve drain valve housing and check clean the valve assembly 7 Normal Harvest Cycle same as the initial harvest cycle Return to step 4 Note Unit continues to cycle until bin control is satisfied or power is switched OFF The pump out cycle can be adjusted to occur every cycle or every 2 5 or 10 cycles The factory default is every 10 cycles The unit always restarts at the 1 minute fill cycle 8 Shutdown Whe
41. installation proper voltage per unit nameplate and adequate water supply As you go through the procedure check to assure the components energize and de energize correctly If not those components and controls are suspect Check for voltage at the 10 pin connector 1 Turn off the power supply then access the control box Clear any ice from bin control bulb 2 Turn on the power supply then move the control switch to the ICE position A 5 second delay occurs 3 One Minute Fill Cycle The inlet water valve is energized After 1 minute the control board checks the float switch If the float switch is closed the unit cycles to harvest If closed continue to step 4 If the float switch is open the unit repeats the 1 minute fill cycle until water enters and the float switch closes low water safety protection during initial start up and at the end of each harvest Diagnosis If the water valve does not open check for no supply voltage at water valve terminals bad coil or plugged screen or external filter no water flow If unit fails to start harvest check for open float switch or bad 1 minute timer in control board 29 4 Initial Harvest Cycle Inlet water valve remains energized contactor coil energizes to start the compressor and fan motor on a remote condenser unit and the hot gas valve energizes The evaporator warms and the thermistor senses 48 F 9 C The control board then receives the thermistor s 3 9 kQ signal
42. insulation panel and the front panel in their correct positions Note When replacing the insulation panel do not catch the hose between the panel and the body 12 Turn on the power supply and start the washing process 13 14 Remove the front panel and the insulation panel 15 Drain the water tank See step 5 above Replace the removed parts and the insulation panel in their correct positions Turn off the power supply after 30 minutes 47 16 Move the control switch to the ICE position 17 Close the cleaning valve Note The icemaker will not operate unless the cleaning valve is completely closed 18 Replace the front panel in its correct position 19 Turn on the power supply to fill the water tank with water 20 Turn off the power supply after 3 minutes 21 Remove the front panel and fully open the cleaning valve 22 Move the control switch to the WASH position 23 Replace the front panel in its correct position 24 Turn on the power supply to rinse off the cleaning solution 25 Turn off the power supply after 5 minutes 26 Remove the front panel and insulation panel 27 Drain the water tank See step 5 above Replace the removed parts and the insulation panel in their correct positions Note Do not replace the insulation panel when you proceed to 2 Sanitizing Procedure 28 Repeat steps 16 through 27 three more times to rinse thoroughly Note If you do not sanitize the icemaker go to s
43. inuity across the float switch leads With the water tank empty the float switch should be open If open continue to step 8 If closed follow the steps in IV D 2 Float Switch Cleaning After cleaning the float switch check it again Replace if necessary 8 Recomnect the black float switch connector to the control board BLACK K5 connector then replace the control box cover in its correct position 9 Move the control switch to the ICE position Replace the insulation panel and the front panel in their correct positions then turn on the power supply After 1 minute the 1 minute fill cycle should end and the initial harvest cycle should begin If the initial harvest cycle begins the float switch is good and the check is complete If the initial harvest cycle does not begin continue to step 10 10 Turn off the power supply 11 Remove the front panel then move the control switch to the OFF position 12 Remove the control box cover 13 Disconnect the black float switch connector from the control board BLACK K5 connector 14 Check for continuity across the float switch leads With the water tank full the float switch should be closed If the float switch is closed and the icemaker will not switch from the 1 minute fill cycle to the initial harvest cycle replace the control board If open confirm that the water tank is full If the tank is not full check the water supply water filters and inlet water valve If the tank is
44. maker off cycle b Control Board 1 Defective 1 See IV B Control Board Check 5 No water comes from a Water Supply Line 1 Water pressure too 1 Check and get spray tubes Water low and water level in recommended pressure pump will not start or water tank too low freeze cycle time is b Inlet Water Valve 1 Dirty mesh filter or 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 2 Clogged 3 Pump out check valve 3 Check assembly and leaking by clean d Pump Motor 1 Motor winding opened 1 Replace 2 Bearing worn out 2 Replace 3 Wiring to pump motor 3 Check for loose connection or open and replace 4 Defective capacitor 14 Replace 5 Defective or bound 5 Replace and clean impeller 6 Mechanical seal worn 6 Check and replace out e Control Board 1 Defective 1 See IV B Control Board Check 38 6 Fan motor will a Fan Motor 1 Motor winding opened 1 Replace not start or is not operating 2 Bearing worn out 2 Replace 3 Wiring to fan motor 13 Check for loose connection or open and replace 4 Defective capacitor 14 Replace 5 Fan blade bound 5 Check and replace b Control Board 1 Defective 1 See IV B Control Board Check 7 All components a Refrigerant 1 Undercharged 1 Check for leaks and run but no ice is recharge produced 2 Air or moisture 2 R
45. motor F S float switch HGV hot gas valve HM headmaster C P R LLV Liquid Line Valve PM pump motor TXV thermostatic expansion valve WV inlet water valve 18 3 Controls and Adjustments CAUTION Dip switches are factory set Failure to maintain factory settings may adversely affect performance and warranty coverage For more information contact Hoshizaki Technical Support at 1 800 233 1940 a Default Dip Switch Settings The dip switch is factory adjusted to the following positions DpSwe No 1 2 s a s o 7 5 5 6 Freeze Timer 9 amp 10 Normally in the OFF position Pump Out Frequency Control 5 amp 6 Pump Out Timer 3 amp 4 Harvest Timer 1 amp 2 b Harvest Timer dip switch 1 amp 2 The harvest timer starts counting when the thermistor reads 48 F 9 C at the evaporator outlet and sends a 3 9 kO signal to the control board No adjustment is required under normal use as the harvest timer is adjusted to the suitable position However a setting longer than the factory setting may be advised in cases where the flush provided at harvest needs to be prolonged for extra cleaning Before changing this setting call the Hoshizaki Technical Support Department at 1 800 233 1940 for recommendations Keep in mind that setting the harvest timer to a longer setting will decrease 24 hour production Dip Switch Setting Time 77 orr or so ON OFF 90 c Pump Out Timer dip s
46. n the unit is running hold ice in contact with the thermostatic bulb the thermostatic bin control switch opens within 10 seconds shutting down the unit The bin control is factory set and generally no adjustment is required However adjustment may be needed in some conditions particularly at higher altitude locations Diagnosis See IV C Bin Control Check 30 B Control Board Check Before replacing a control board that does not show a visible defect and that you suspect is bad always conduct the following check procedure This procedure will help you verify your diagnosis Alarm Reset If the control board is in alarm beeping press the ALARM RESET button on the control board while the control board is beeping WARNING Risk of electric shock Care should be taken not to touch live terminals Once reset the unit starts at the 1 minute fill cycle For audible alarm information see II C 2 LED Lights and Audible Alarm Safeties 1 Check the dip switch settings to assure that S4 dip switch 3 4 7 8 9 amp 10 and S5 dip switch 1 through 5 are in the factory default position S4 dip switch 1 2 5 4 6 are cleaning adjustments and the settings are flexible For factory default settings see 11 C 3 Default Dip Switch Settings 2 Move the control switch to the ICE position If the red POWER OK LED is on the control voltage is good If the red POWER OK LED is off clear ice away from the thermostatic bin control bulb in
47. oes not finish 2 Coil winding opened 2 Replace 3 Wiring to water valve 3 Check for loose connection or open and replace Control Board 1 Defective 1 See IV B Control Board Check Cleaning Valve 2 Bad contacts 2 Check for continuity and replace n Wash Switch 1 WASH position 1 Move to ICE position 2 Check and replace a Float Switch 1 Connector 1 Place in position disconnected 2 Leads opened or 2 Check and replace defective switch 3 Float does not move 3 Clean or replace freely b Control Board 1 Replace 37 3 Compressor will a Magnetic Contactor 1 Bad contacts 1 Check for continuity and not start or stops replace operating 2 Coil winding opened 2 Replace b Start Capacitor or Run 1 Defective 1 Replace Capacitor c Internal Overload 1 Loose terminal 1 Tighten or replace Protector Open check 1 through 3 to the right 2 Voltage 2 Check and correct and d through f below 4 Dirty condenser 3 Clean d Starter 1 Check and replace 2 Coil winding opened 2 Replace e Compressor 1 Wiring to compressor 1 Check for loose connection or open and replace 2 Defective 2 Replace 3 Protector tripped 3 Reduce temperature f Control Board 1 No power to contactor 1 See IV B Control Board Check 4 Water continues to a Inlet Water Valve 1 Diaphragm does not 11 Check for water leaks with be supplied in freeze close ice
48. rements Failure to meet these code requirements could result in death electric shock serious injury fire or severe damage to equipment This unit requires an independent power supply See the nameplate for proper voltage and breaker fuse size Failure to use a proper breaker or fuse can result in a tripped breaker blown fuse or damage to existing wiring This could lead to heat generation or fire THE ICEMAKER MUST BE GROUNDED Failure to properly ground the icemaker could result in death or serious injury Move the control switch to the OFF position and turn off the power supply before servicing Lockout Tagout to prevent the power supply from being turned back on inadvertently Do not make any alterations to the unit Alterations could result in electric shock injury fire or damage to the unit Additional Warning for Remote Air Cooled Model THE REMOTE CONDENSER UNIT MUST BE GROUNDED The power supply and ground wire to the remote condenser unit are supplied from the icemaker Failure to properly ground the remote condenser unit could result in death or serious injury I Specifications A Icemaker 1 KM 1601MRH with URC 21F AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 l
49. tep 9 in 2 Sanitizing Procedure 2 Sanitizing Procedure Following Cleaning Procedure 1 Dilute a 5 25 sodium hypochlorite solution chlorine bleach with water Add 2 5 fl oz 74 ml of sanitizer to 5 gal 19 1 of water 2 Pour the sanitizing solution into the water tank 3 Replace the insulation panel and the front panel in their correct positions Note Make sure that the control switch is in the WASH position and the cleaning valve is open 4 Turn on the power supply and start the sanitizing process 5 6 7 Drain the water tank See step 5 in 1 Cleaning Procedure Replace the removed parts and the insulation panel in their correct positions 8 Repeat steps 16 through 27 in 1 Cleaning Procedure two times to rinse thoroughly Turn off the power supply after 15 minutes Remove the front panel and the insulation panel 9 Close the cleaning valve 10 Move the control switch to the ICE position 11 Replace the front panel in its correct position 12 13 Clean the storage bin with water Turn on the power supply and start the automatic icemaking process 48 B Maintenance IMPORTANT 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
50. the unit may not operate correctly The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze up issues Upon termination of freeze timer machine initiates the harvest cycle After 2 consecutive timer terminations machine will shut down possibly indicating a problem The freeze timer is factory adjusted and no adjustment is required Time Lor orr a ON D Control Switch The control switch has three positions OFF for power off ICE for icemaking and WASH to activate the water pump when cleaning and sanitizing 21 Ill Technical Information A Water Circuit and Refrigeration Circuit 1 KM 1601MRH KM 1601MRH3 PNOO JeyeAA 3uejeBuje mo dung UOMAS a 929914 HAIBA A99YO A PA Sec JOH YOJMS inss ld nlci ost H Jojsiuugu L i iL iil SSeooy DE Sa eli hh Jasuapuod Ag Addns JIM eA BA Buluea o SA EA Bunosuuo eqni y n jesuepuo5 Joje nbay eunsseJg Buisuapuo9 22 B Wiring Diagrams 1 KM 1601MRH
51. ts begin timing the harvest cycle 12 The harvest timer should expire and terminate the harvest cycle within 2 to 3 minutes If the harvest timer does not expire and terminate the harvest cycle the harvest timer is bad and the control board should be replaced 35 F Diagnostic Charts Before consulting the diagnostic charts check for correct installation proper voltage per unit nameplate and adequate water supply Check CB using the steps in IV B Control Board Check Check the dip switch settings to assure that S4 dip switch 3 4 7 8 9 10 are in the factory default position S4 dip switch 1 2 5 6 are cleaning adjustments and the settings are flexible For factory default settings see II C 3 a Default Dip Switch Settings 1 No Ice Production 1 The icemaker will not a Power Supply 1 OFF position 1 Move to ON position 3 Bad contacts 3 Check for continuity and replace 4 Voltage too high or too 4 Check and get low recommended voltage b Fuse Inside fused 1 Blown 1 Check for short circuit and disconnect if any replace c Control Switch 1 OFF position 1 Move to ICE position 2 Bad contacts 2 Check for continuity and replace d Bin Control Thermostat 1 Tripped with bin filled 1 Remove ice with ice 2 Ambient temperature 2 Increase ambient too cool temperature 3 Set too warm 3 See IV C Bin Control Check 4 Bulb out of position 4 Place in position 5 Bad contacts
52. und the thermostatic bulb to warm it up 6 Check for continuity across the thermostatic bin control switch If closed continue to step 6 If open adjust or replace the thermostatic bin control 7 With the multimeter test leads still in place hold ice on the thermostatic bin control bulb to lower the temperature Within 10 seconds the thermostatic bin control switch should open no continuity If it remains closed adjust or replace the thermostatic bin control 32 D Float Switch Check and Cleaning The float switch is used to determine that there is sufficient water in the tank after the 1 minute fill cycle and after each harvest cycle The float switch is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle No adjustment is required 1 Float Switch Check To check the float switch follow the steps below 1 Turn off the power supply 2 Remove the front panel then move the control switch to the OFF position 3 Remove the insulation panel then remove the drain plug located on the lower front part of the ice chute See Fig 1 Allow the water tank to drain 4 Replace the drain plug in its correct position Be careful not to cross thread it D 5 Remove the control box cover Ice Chute Float Switch Assembly Drain Plug 6 Disconnect the black float switch Fig 1 connector from the control board BLACK K5 connector 7 Check for cont
53. upply and turn it on after 3 minutes The harvest 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 first removing the thumbscrew lifting the panel slightly and Overflow Pipe pulling it toward you Rubber Cap 5 Drain the water tank by removing the rubber cap covering the overflow pipe in the water tank Remove the overflow pipe Fig 3 by turning it counterclockwise See Fig 3 6 Replace the removed parts in their correct positions 7 In bad or severe water conditions clean the float switch assembly as described below Otherwise continue to step 8 a Remove the float switch assembly from the mounting bracket and remove the rubber boot from the bottom of the assembly b Remove the retainer rod from the bottom of the float switch assembly then remove the float Be careful not to bend the retainer rod excessively when removing it c Wipe down the float switch assembly s housing shaft float and retainer rod with cleaning solution Wipe the inside of the rubber boot with cleaning solution d Reassemble the float switch assembly and replace it and the rubber boot in their correct positions 8 Pour the cleaning solution into the water tank 9 Fully open the cleaning valve on the left side wall of the machine compartment 10 Move the control switch on the control box to the WASH position 11 Replace the
54. vity 49 6 Attach compressed air or carbon dioxide supply to the potable water line drain valve 7 Move the control switch to the ICE position 8 Blow the potable water line out using compressed air or carbon dioxide 2 Drain the potable water tank 1 Turn off the power supply 2 Move the control switch to the OFF position 3 Drain the water tank by removing the insulation panel and the rubber cap covering the overflow pipe in the water Overflow Pipe tank Remove the overflow pipe by turning it counterclockwise See Fig 4 Rubber Cap 4 Replace the removed parts in their correct ositions P Fig 4 5 Remove all ice from the storage bin and clean the storage bin 6 Replace the front panel in its correct position 7 Close the drain valve 50
55. witch 3 amp 4 When a freeze cycle is completed the pump motor stops and the icemaker resumes operation in 2 seconds Then during cycles when a pump out is called for the pump motor drains the water tank for the time determined by the pump out timer The pump out timer also acts in place of the harvest timer during cycles with a pump out The pump out timer is factory adjusted and no adjustment is required Dip Switch Setting Time seconds T1 Time to drain the water tank T2 Harvest timer at pump out Pump out always occurs on the 2nd harvest after startup Then depending on the pump out frequency control setting dip switch 5 amp 6 pump out occurs every cycle or every 2nd 5th or 10th cycle d Pump Out Frequency Control dip switch 5 amp 6 The pump motor drains the water tank at the frequency set by the pump out frequency control The pump out frequency control is factory adjusted to drain the water tank every 10 cycles and no adjustment is required However where water quality is bad and the icemaker needs a pump drain more often the pump out frequency can be adjusted as shown in the table below Dip Switch Setting Frequency OFF every 2 cycles every 5 cycles every 10 cycles e Factory Use S4 dip switch 7 amp 8 Factory set for proper operation Do not adjust This must be left in the factory default position 20 f Freeze Timer dip switch 9 8 10 CAUTION Adjust to proper specification or
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