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KMD-201AA SERVICE MANUAL

1. 5 FREEZE a a 5 d DRAIN CYCLE 5 e NORMAL HARVEST CYCLE 6 CONTROL BOARD 8 CONTROL BOARD 9 lefu US 10 c CONTROLS AND 5 12 d CONTROL BOARD CHECK PROCEDURE 17 e CONTROL BOARD REPLACEMENT 17 4 HARVEST CONTROL THERMISTOR 18 5 FLOAT 19 a EXPLANATION OF OPERATION 19 PI CLEANING wissiena 19 FLOAT SWITCH CHECK PROCEDURE 19 IN INT 20 a EXPLANATION OF OPERATION 20 b BIN CONTROL CHECK PROCEDURE
2. 20 T OWITOHE E 21 a CONTROL SWITCH 21 b SERVICE 5 21 Il TECHNICAL INFORMATION 22 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 22 2 WIRING DIAGRAM 23 9 MMING CHAR esas 24 IV SERVICE DIAGNOSIS 25 1 10 MINUTE DIAGNOSTIC PROCEDURE 25 2 DIAGNOSTIC CHART 27 a NO ICE PRODUCTION eenen 27 6 EVAPORATOR IS FROZEN nennen 30 c LOW ICE 31 d ABNORMAL 1 eaa 31 OTHER S R R R AA 32 V REMOVAL AND 33 1
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4. 57 SPECIFICATIONS 1 SPECIFICATIONS a KMD 201AA air cooled AC SUPPLY VOLTAGE 1 PHASE 220 240 230 50 60Hz F037 2039 50Hz F038 2040 60Hz AMPERAGE 3 0 3 6 A AT 32 C WT 21 C STARTING AMPERAGE 25 25 ELECTRICAL CONSUMPTION 700 810 W AT 32 C WT 21 C POWER FACTOR 95 95 POWER SUPPLY CAPACITY Min 1 57 kVA 6 8A Approx 190 205 kg AT 10 WT 10 ICE PRODUCTION PER 24h Approx 167 182 kg AT 21 WT 15 Approx 135 157 kg AT 32 WT 21 Approx 0 90 0 98 m AT 10 WT 10 WATER CONSUMPTION PER 24h Approx 0 40 0 48 m AT 21 WT 15 Approx 0 27 0 31 m AT 32 WT 21 SHAPE OF ICE CRESCENT CUBE FREEZE CYCLE TIME Approx 30 6 27 7 Min AT 21 WT 15 ICE PRODUCTION PER CYCLE Approx 3 8 3 8 kg 416pcs AT 21 C WT 15 DIMENSIONS 560mm W X 625mm D X 610mm H not incl Bin Sw EXTERIOR Stainless Steel Plastic Frame Front Galvanized Steel Rear INSULATION Polyurethane Foam CONNECTIONS ELECTRIC X type Connection WATER SUPPLY Inlet 1 2 connected at rear side DRAIN Outlet 3 4 connected at rear side HARVESTING SYSTEM Water Supply Harvest Cycle and Hot Gas Defrost COMPRESSOR Hermetic 560W Model NT6217GK CONDENSER Air cooled Fin and Tube type HEAT REJECTION 1410W 1220kcal h AT 32 C WT 21 EVAPORATOR Vertical type Stainless Steel and Copper REFRIGERANT CONTROL
5. 2 Water continues to be supplied and the icemaker will not start 3 Compressor will not start or stops operating d Starter 1 Bad contacts 1 Check and replace 2 Coil winding opened e Compressor 1 Power supply not 1 Refer to nameplate and within specifications correct 2 Wiring to compressor 2 Check for loose connection or open and replace 28 Problem Cause 3 Compressor will not start or stops operating continued e Compressor 3 Defective 3 Replace continued pou 4 Protector tripped 4 Reduce temperature f Control Board 1 No power to contactor 1 See II 3 d Control Board Check Procedure 4 Water continues to 1 high be supplied in freeze b Fill or Harvest Water 1 Diaphragm does not 1 Check for water leaks with cycle Valve icemaker off Board Check Procedure a Pump Motor 1 Motor winding 1 Replace opened 2 Bearing worn out 2 Replace 3 Wiring to pump motor 3 Check for loose connection or open and 5 Water pump will not start replace 4 Defective capacitor 4 Replace 5 Replace and clean 5 Defective or bound impeller b Control Board 1 Defective 1 See Il 3 d Control Board Check Procedure c Control Switch 1 Bad contacts 1 Replace 6 Freeze cycle time 15 a Drain Valve 1 Leaking by 1 Clean or replace too short b Float Switch 1 Dirty or erra
6. 2 All ice formed on h Control Board 2 Defective 1 See Il 3 d Control evaporator does not continued Board Check Procedure fall into bin in harvest water Regulating 1 Leaking by in harvest 1 Check and replace cycle continued water cooled model only 3 Spray Tubes 1 Clogged 2 Out of position 2 Place in position DJ Water System 1 Diry 2 Water supply line 2 Increase water line size too small requires 3 8 OD line dedicated per machine 3 Water filter flow 3 Replace with filter that has too small larger flow rate c Refrigerant 1 Low charge 1 Check for leaks and recharge d Expansion Valve 1 Bulb out of position or 1 Place in position loose attachment 2 Defective 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 c LOW ICE PRODUCTION Problem Possible Cause 1 Freeze cycle time is a See chart b 1 and check float switch fill and harvest water valves control long board water pump spray tubes evaporator and expansion valve b See chart a 1 and check dirty air filter or condenser ambient or water temperature refrigerant charge water pressure and condenser water regulating valve water cooled model only
7. HOSHIZAKI MODULAR CRESCENT CUBER MODEL KMD 201AA KMD 201AWA SERVICE MANUAL IMPORTANT This manual should be read carefully before the 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 PAGE k OPECIFIGA THON E 1 1 5 1 KMD 201AA 1 0 KMD 201 AWA water cooled 2 Il GENERAL 3 t CONSTRUC TION setenta meitoe e 3 201 3 b 201 4 2 SEQUENCE OF 5 ONE MINUTE FILL CYCLE MMMMMM 5 b INITIAL HARVEST
8. 1 Replace or shorted Problem Possible Cause 1 Loose connections or 1 Check for continuity and 1 The icemaker will not h Wiring to Control Board start continued open replace i Thermistor Leads shorted 1 See Il 4 Harvest Control opened and high Thermistor temperature or harvest backup timer safety operates 1 beep or 2 beep alarm Hot Gas Valve Continues to open 1 Check for hot gas valve in freeze cycle and stuck open and replace freeze timer safety operates 3 beep alarm k Harvest Water Valve Mesh filter or orifice 1 Clean gets clogged and water supply cycle does not finish Coil winding opened 2 Wiring to water valve 3 Check for loose connection or open and replace Control Board Defective or in alarm 1 See 3 d Control Board Check Procedure a Float Switch 1 Connector 1 Reconnect disconnected 2 Check and replace Float does not move 3 Clean or replace freely b Control Board 1 Defective 1 3 d Control Board Check Procedure a Magnetic Contactor 1 Bad contacts 1 Check for continuity and replace 2 Coil winding opened 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 to the right 2 Voltage 2 Check and correct and d through f below 3 Dirty condenser
9. 5 amp 6 are cleaning adjustments and the settings are flexible 2 Move the control switch to the ICE position and check for proper control voltage If the POWER OK LED is on the control voltage is good If the POWER OK LED is off check the control transformer circuit If no voltage is present check the power supply circuit 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 should be 5 6 7 8 9 4 Some components e g the compressor will cycle during the test Each LED flashes three times in 5 seconds LED 5 continues to flash while LED 6 flashes Following the output test sequence the icemaker will resume normal operation beginning with the 1 minute fill cycle e CONTROL BOARD REPLACEMENT The dip switches should be adjusted to the factory default settings as outlined in this manual 4 HARVEST CONTROL THERMISTOR A thermistor semiconductor is used as a harvest control sensor anti slush sensor and overfreeze sensor The resistance varies depending on the suction line temperatures The thermistor detects the temperature of the evaporator outlet to start the harvest timer to momentarily stop the pump motor during the freeze cycle or to extend the harvest cycle time No adjustment is required If necessary check for resistance between thermistor leads and visually check the thermistor m
10. Install the new valve Replace the removed parts in the reverse order of which they were removed If replacing the harvest and or fill water valve make sure the washer is in place in the fitting nut 8 If replacing the harvest and or fill water valve close the icemaker water supply line drain valve Open the icemaker water supply line shut off valve 9 Turn on the power supply 10 Check for leaks 11 Replace the panels in their correct positions 13 DRAIN VALVE 1 Turn off the power supply 2 Close the water supply tap 3 Remove the panels 4 Disconnect the connector of the drain valve lead 5 Remove the hose clamps at the inlet and outlet sides 6 Remove the rubber hoses at the inlet and outlet sides 43 7 Remove the two mounting screws 8 Install the new valve in the reverse order of the removal procedure 9 Open the water supply tap 10 Plug in the icemaker or connect the power source 11 Check for leaks 12 Refit the panels in their correct positions 14 WATER TANK 1 Remove the front panel then remove the front insulation 2 Loosen the two thumbscrews securing the pump motor bracket 9 Jl CL Ti p Float Switch Connector Discharge Hose LU Pump Motor r7 Connector 16 LA ipt Thumbscrews Snap Tab Pump Motor Bracket 3 Move the control switch to the SERVICE position Mo
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12. SERVICE FOR REFRIGERANT LINES cece ets et ated 33 a SERVICE 33 b REFRIGERANT 34 c EVACUATION AND 34 2 74 35 3 COMPRESSOR 35 4 V A AA 36 5 HOT GAS VALVE nnns ne 37 6 EXPANSION VALVE 38 7 39 8 WATER REGULATING VALVE WATER COOLED MODEL ONLY 40 9 ADJUSTMENT OF WATER REGULATING VALVE WATER COOLED iy 41 10 FAN MOTOR nennen eno 41 11 PUMP 1 1 42 IA VISA 43 KM EZ R5 43 14 WATER TANK 44 15 FLOAT SWITCH ee ee ee nenne esee 45 16 BIN CONTROL SWITCH ese seen 46 17 THERMISTOR 47 18 CONTROL Sea S 48 CONTROL amp SERVI
13. Ver 2 0 Deactivated p Anti Slush Control S2 dip switch 6 Program Ver 3 2 Do not adjust This must be left in the factory default position or the unit will not operate properly When activated Ver 1 1 the thermistor located on the suction line checks for a 41 F 5 C temperature as the evaporator cools When 41 F 5 C is reached a 4 8 signal causes the control board to de energize the pump motor for 10 seconds When activated Ver 2 0 the thermistor located on the suction line checks for a 50 F 10 C temperature as the evaporator cools When 50 F 10 C is reached a 3 9 signal causes the control board to de energize the pump motor for 10 seconds and energize it for 50 seconds repeatedly When 34 F 1 C is reached a 5 9 signal causes the control board to de energize the pump motor for 10 seconds energize it for 50 seconds de energize it again for 10 seconds then energize it continuously 52 Dip Switch Setting Anti Slush Control Ne6 No 6 Activated Ver 1 1 Activated Ver 2 0 CONTROL BOARD CHECK PROCEDURE Before replacing a control board that does not show a visible defect and that you suspect is bad always conduct the following check procedure This procedure will help you verify your diagnosis 1 Check the dip switch settings to assure that S1 dip switch 3 4 7 8 9 amp 10 and S2 dip switch 1 through 6 are in the factory default position S1 dip switch 1 2
14. b Bin Control Check Procedure a Pump Motor 1 Bearings worn out 1 Replace 1 Bearings worn out 1 Replace 2 Fan blade deformed 2 Replace 3 Fan blade does not 3 Replace move freely 1 Bearings worn out 1 Replace cylinder valve broken 2 Mounting pad out of 2 Reinstall position 1 Rub or touch other 1 Reposition lines or surfaces T Plugged 1 Drains not run separately 1 Separate the drain lines 1 Out of position Circulated water falls into dispenser unit storage bin 1 Place in position 32 V REMOVAL AND REPLACEMENT 1 SERVICE FOR REFRIGERANT LINES a SERVICE INFORMATION 1 Allowable Compressor Opening Time and Prevention of Lubricant Mixture R404A The compressor must not be opened more than 15 minutes in replacement or service Do not mix lubricants of different compressors even if both are charged with the same refrigerant except when they use the same lubricant 2 Treatment for Refrigerant Leak R404A If a refrigerant leak occurs in the low side of an ice maker air may be drawn in Even if the low side pressure is higher than the atmospheric pressure in normal operation a continuous refrigerant leak will eventually lower the low side pressure below the atmospheric pressure and will cause air suction Air contains a large amount of moisture and ester oil easily absorbs a lot of moisture If an ice maker charged with R404A has possibly drawn in air
15. c Check pump hot gas valve headmaster C P H remote air cooled model only expansion valve refrigeration check valve and compressor 2 Harvest cycle time is a See chart b 2 and check evaporator water supply line harvest water valve ambient and or water temperature line valve if applicable thermistor control board and hot gas valve d ABNORMAL ICE Possible Cause 1 Small cubes a Ice Cube Guide 1 Out of position 1 Place in position Water Tank Circulated water falls Deflector into dispenser unit storage bin b See chart 1 5 and check water supply line inlet water valve water system pump motor and control board 31 continued c Drain Valve 2 Cloudy or irregular cubes B a See chart b 1 amp 3 and check float switch fill and harvest water valves control board spray tubes water system refrigerant charge and expansion valve Spray Guide Water Quality e OTHER 1 Install a water softener or filter 1 High hardness or contains impurities Possible Cause 1 lcemaker will not stop a Bin Control when bin ts filled with ice 2 Abnormal noise b Fan Motor except water cooled model c Compressor d Refrigerant Lines 3 ce in dispenser a Drain Line s unit storage bin often b Icemaker and melts Bin C Ice Cube Guide Water Tank Deflector Dispenser Unit Storage 1 Defective 1 See Il 6
16. pesn YOUMS eoj Joddn 9 6 uoiMS LOZ GWM 40 11491 dip LS OL pesn YOUMS 60 J9MO JO 195 4 Buas 22291 9z99JJ i 9155 v 81245 azaay app lt sdajs apin ajap 1 2 Lo juauocduiro2 PUE aouanbas YMYLOZ VV VOZ GOIAM 3 CONTROL BOARD A HOSHIZAKI exclusive solid state control is employed in KMD 201AA and KMD 201AWA Crescent Cubers All models are pretested and factory adjusted CAUTION 1 Fragile handle very carefully 2 A 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 board 3 Do not touch the electronic devices on the board or the back of the board to prevent damage to the board 4 Do not change wiring and connections 5 Always replace the whole board assembly if it goes bad 6 Do not short out power supply to test for voltage a CONTROL BOARD LAYOUT Control Board Relay LEDs 6 Connector K7 indicate which relays Transformer are energized as listed below LED 5 X1 Relay Compressor Comp Remote Fan Motor FMR LED 6 X2 Relay Hot Gas Valve HGV Self Contained Fan Moto
17. 7 Remove the front panel then remove the front insulation the large insulation panel in front of the evaporator by lifting up the panel slightly and pulling it towards you 8 In bad or severe water conditions clean the float switch as described below Otherwise continue to step 9 a Loosen the two thumbscrews securing the pump motor bracket LS Float Switch Connector Discharge Hose Pump Motor Connector a Thumbscrews Snap Tab Pump Motor Bracket b Disconnect the discharge hose c Disconnect the pump motor connector and the float switch connector from the side of the control box d Keep pushing up the snap tab at the right side of the pump motor bracket e Pull out the water tank cube guide pump motor bracket pump motor and float switch together Jr Float Switch q Cube Guide Snap f Remove the pump motor bracket securing the pump motor and the float switch Remove the float switch from the pump motor bracket 54 g Wipe down the float switch housing shaft and float with cleaning solution Rinse the parts thoroughly with clean water h Replace the float switch in its correct position i Replace the removed parts in the reverse order of which they were removed 9 Pour the cleaning solution into the water tank 10 Move the service switch to the WASH position 11 Replace the front insulation and the front panel in their correct positi
18. Drain Timer S1 dip switch 3 amp 4 Once every ten freeze cycles the drain valve opens to drain the water tank for the time determined by the drain timer These switches also determine the time to delay completion of a defrost cycle i e the minimum defrost time Do not change this setting or the unit will not operate properly or produce high quality ice Dip Switch Setting Time seconds OFF ON 20 120 N T1 Time to drain the water tank T2 Harvest timer at drain Drain cycle always occurs on the 2nd harvest after startup Then depending on the drain frequency control setting dip switch 5 amp 6 drain cycle occurs every cycle or every 2nd 5th or 10th cycle d Drain Frequency Control 51 dip switch 5 amp 6 The water tank drains at the frequency set by the drain frequency control The drain 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 drain more often the drain frequency can be adjusted as shown in the table below Dip Switch Setting 27 every 2 cycles every 5 cycles e Water Saver Timer S1 dip switch 7 amp 8 The water saver timer allows the water valve to close and the pump motor to circulate water in the tank during the final part of harvest The water valve is open during harvest for a maximum of 6 minutes or the length of harvest minus 0 10 30 or 50 seconds
19. OFF center position ICE upper position and SERVICE lower position b SERVICE SWITCH When the control switch is placed in the SERVICE position power is supplied to the service switch The service switch can be used to perform two functions draining the tank DRAIN lower position and washing the icemaking compartment or CIRCULATE upper or center position Both the WASH and CIRCULATE positions activate the same function of washing the icemaking compartment The service switch is activated in any of the three positions when the power is supplied to the pump motor 1 DRAIN KMD 201AA and KMD 201AWA employ the pump out drain system When the service switch is active and placed in the lower position power is supplied to the pump motor and drain valve 2 WASH or CIRCULATE When the service switch is active and placed in the upper or center position power is supplied to the pump motor This function is to clean the evaporator plate 21 Ill TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT Evaporator Af Cube Guide Water Regulating Valve Condenser E Drain Water Supply PET High Pressure Condenser Switch Harvest Water LELILEFEILLILILIIELE Valve Spray Tube Fill Water Valve d s s 4 Not provided for later production Ac
20. To prevent deformation do not hit the fan on the condenser or other parts 6 Install the new fan motor in the reverse order of the removal procedure 41 7 Replace the panels in their correct positions Screw Screw Loosen Remove 8 Turn on the power supply Fan Motor Fan Blade Cover Fan Motor Bracket 11 PUMP MOTOR 1 Turn off the power supply 2 Remove the panels and front insulation 3 Disconnect the connector of the pump motor lead 4 Remove the thumbscrew securing the pump motor 5 Remove the hose band connecting the discharge hose 6 Slide the pump motor at right slightly and lift it up towards you Hose Band Thumbscrew Discharge Hose Pump Motor 7 Remove the hose band connecting the discharge outlet and pull off the rubber hose 8 Install the new motor in the reverse order of the removal procedure 9 Replace the panels and front insulation in their correct positions 10 Turn on the power supply 12 WATER VALVE 1 Turn off the power supply 2 If replacing the harvest and or fill water valve close the icemaker water supply line shut off valve Open the icemaker water supply line drain valve 3 Remove the panels 4 Disconnect the tubing attached to the valve If replacing the harvest and or fill water valve loosen the fitting nut Be careful not to lose the washer 5 Disconnect the terminals from the valve 6 Remove the bracket and valve from the unit 7
21. WATER SUPPLY DRAIN ICE MAKING SYSTEM Vertical Evaporator with water flow on both sides HARVESTING SYSTEM Water Supply Harvest Cycle and Hot Gas Defrost COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE ICE MAKING CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL SYSTEM BIN CONTROL SYSTEM ELECTRICAL PROTECTION BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION PACKAGE ACCESSORIES OPERATION CONDITIONS VOLTAGE RANGE AMBIENT TEMP WATER SUPPLY TEMP WATER SUPPLY PRESS We reserve the right to make changes in specifications and design without prior to notice 1 PHASE 220 240 230V 50 60Hz F022 F024 50Hz F023 2025 60Hz 2 5 3 3 A AT 32 C WT 21 C 25 25A 589 758 W AT 32 C WT 21 C 98 98 Min 1 57 kVA 6 8A Approx 190 208 kg AT 10 WT 10 Approx 170 192 kg AT 21 C WT 15 Approx 155 175 kg AT 32 C WT 21 Approx 0 43 0 51 m AT 10 WT 10 Approx 0 32 0 36 m AT 21 WT 15 Approx 0 30 0 33 32 C WT 21 Approx 0 83 1 03 m AT 10 WT 10 1 16 1 36 1 82 2 20 CRESCENT CUBE Approx 32 0 28 0 Min AT 21 C WT 15 C Approx 3 9 4 0 kg 416pcs AT 21 C WT 15 C 560mm W X 625mm D X 610mm H not incl Bin Sw Stainless Steel Plastic Fra
22. and e sequence until the bin control is activated and shuts the unit down When the bin control is activated the POWER OK LED flashes Note To prevent incomplete batches of ice from foaming on the evaporator the control board will only shut down the machine within the first 5 minutes of the freeze cycle after the thermistor temperature reaches 2 C If ice pushes the bin control actuator in open after this minimum freeze period the control board will allow the machine to complete the freeze cycle and the following harvest cycle before shutting down the machine Legend Comp compressor DV drain valve FMS self contained fan motor FWV fill water valve HGV hot gas valve HWV harvest water valve LF S lower float switch contacts UF S upper float switch contacts PM pump motor Joyesodens JO pue Sy 1 7 pue aues pasn si 4141 AIBA JayeM S 96 UO9 Jeddn s 4n pue 1o0jouu 5 si uonisod 32 AMH3S 941 ul pesed si quodis eui uauAA 100w Wd S 26 UOO U91IAS J9M0 6 41 49011504 3 3 SI 01u09 ol pezib1ou3 sjueuod JSOAJEY AMH seb 104 ASH AMA JOJOW 2 SINS
23. and de energize correctly If not those components and controls are suspect 1 Turn power off and access the control box Clear any ice from the bin control actuator located in the bin 2 Turn power on and place the control switch in the ICE position A 5 second delay occurs The POWER OK LED on the control board comes on If the POWER OK LED is flashing indicating a full bin check the bin control See 6 B BIN CONTROL CHECK PROCEDURE 3 One Minute Fill Cycle The harvest water valve is energized After 1 minute the control board checks the float switch If the lower float switch is closed the unit cycles to harvest If closed continue to step 4 If the lower float switch is open the unit repeats the 1 minute fill cycle until water enters and the lower 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 board 4 Initial Harvest Cycle The harvest 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 The control board then receives the thermistor s 3 9 kO si
24. control board 3 Install the new control board in the reverse order of the removal procedure 4 Check the dip switch for proper setting 5 When reconnecting the connectors do not push them too hard The control board may be damaged MAGNETIC CONTACTOR 1 Disconnect the tab terminals remove the mounting screw or pull the tub of bracket to release the magnetic contactor and lift off the magnetic contactor 2 Install the new magnetic contactor in the reverse order of the removal procedure ff CONTROL BOARD TRANSFORMER 1 Disconnect the connectors and closed end connectors connecting the control board The tie securing the harness may be removed But be careful not to break the lead wires 2 Remove the mounting screws 3 Install the new transformer in the reverse order of the removal procedure 50 0 STARTER 1 Disconnect the terminals remove the mounting screw 2 Install the new starter in the reverse order of the removal procedure 3 To prevent miswiring check the terminal numbers and lead wire colors with the wiring label h RUN CAPACITOR 1 Disconnect the terminals on the starter and remove the nut securing the run capacitor 2 Install the new run capacitor in the reverse order of the removal procedure 3 To prevent miswiring check the terminal numbers and lead wire colors with the wiring label i START CAPACITOR 1 Disconnect the terminals on the starter and remove the nut securing the run ca
25. determined by the water saver timer setting whichever is shorter When the water valve closes the pump motor energizes and runs for the time determined by the water saver timer setting The water saver timer is factory adjusted and no adjustment is required Dip Switch Setting Time f Freeze Timer S1 dip switch 9 amp 10 CAUTION Adjust to proper specification or 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 lip Switch Setting Time 50 60Hz No 10 minutes 60 60 g Pump Out Pump Motor Delay S2 dip switch 1 The pump out pump motor delay determines whether or not the pump motor de energizes for 2 seconds before restarting at the beginning of a drain cycle The pump out pump motor delay is factory adjusted and no adjustment is required 52 Dip Switch Setting Delay No 1 seconds OFF Control Board P00013 02 h Refill Counter S2 dip switch 2 3 amp 4 Program Ver 2 5 or earlier Do not adjust These must be left in the factory default position or the unit will not operate properly The KMD 201AA and KMD 201AWA refill 1 time i Factory Use S2 Dip Switch 5 Program V
26. nameplate for the required refrigerant charge 15 Connect the terminals and replace the terminal cover in its correct position 16 Replace the panels and water tank in their correct positions 17 Turn on the power supply Note Hoshizaki recommends that compressor starting electrics are always replaced at the same time as the compressor 4 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 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the drier holder if any and pull the drier toward you for easy service 36 5 Remove the drier using brazing equipment 6 Braze the new drier with the arrow on the drier in the direction of the refrigerant flow Use nitrogen gas at a pressure of 20 to 30 kPa when brazing tubings Braze in an access valve using a tee if necessary 7 Check for leaks using nitrogen gas 970 kPa and soap bubbles 8 Evacuate the system and charge it with refrigerant see V 1 c EVACUATION AND RECHARGE 9 Refit the panels in their correct positions 10 Turn on the power supply Note Always use a drier of the correct capacity and refrigerant type 5 HOT GAS VALVE CAUTION ensure optimum performance use a copper tube of the same diameter and length for replacement of t
27. of a harvest cycle is 48 F 9 C or less the harvest cycle is extended for 30 seconds If the difference between the temperature at the beginning of a freeze cycle and the minimum temperature after 30 seconds in the freeze cycle is 2 5K or more and less than 3 5K the next harvest cycle is extended for 30 seconds If the above conditions occur in Succession the number of occurrence times 30 seconds will be added to the harvest cycle time If the above temperature difference is 3 5K or more the freeze cycle ends after the minimum freeze cycle time and a harvest cycle starts 52 Dip Switch Setting Overfreeze Detection No 5 Control Deactivated Activated Anti Slush Control S2 dip switch 6 Program Ver 3 1 Do not adjust This must be left in the factory default position or the unit will not operate properly It is deactivated on the KMD 201 series When activated Ver 2 0 the thermistor located on the suction line checks for a 50 F 10 temperature as the evaporator cools When 50 10 is reached a 3 9 signal causes the control board to de energize the pump motor for 10 seconds and energize it for 50 seconds repeatedly When 34 F 1 C is reached a 5 9 signal causes the control board to de energize the pump motor for 10 seconds energize it for 50 seconds de energize it again for 10 seconds then energize it continuously 52 Dip Switch Setting Anti Slush Control Oo No6 __ No 6 Activated
28. switch should be cleaned and checked before replacing First disconnect the float switch connector from the control box and remove the water tank and pump motor bracket together from the icemaker Twist the mechanical lock inside of the pump motor bracket and remove the float switch See V 15 FLOAT SWITCH Remove the retainer clip from the shaft and slide the float off the shaft Soak the switch assembly in ice machine cleaner Wipe down the shaft float housing with cleaning solution See VI CLEANING AND MAINTENANCE INSTRUCTIONS c FLOAT SWITCH CHECK PROCEDURE Before replacing a float switch that you suspect is bad make sure the float switch has been cleaned This procedure will help you verify your diagnosis The float switch has three wires The black wire is common The blue wire is for the lower float switch contact and the red wire is for the upper float switch contact 1 Disconnect the black float switch connector from the control box 2 Drain the reservoir water 3 Turn the control switch to ICE 4 As water fills the reservoir the float switch contacts should close Check continuity of the lower float switch contacts using the black and blue wires and the upper float switch contacts using the black and red wires With the float positioned all the way up both float switch contacts should be closed If either float switch contact fails the assembly should be replaced 5 Turn the control switch to OFF 6 Drain th
29. the drier must be replaced Be sure to use a drier designed for 404 3 Handling of Handy Flux R404A Repair of the refrigerant circuit requires brazing It is no problem to use the same handy flux that has been used for the current refrigerants However its entrance into the refrigerant circuit should be avoided as much as possible 4 Oil for Processing of Copper Tubing R404A When processing the copper tubing for service wipe off oil if any used by using alcohol or the like Do not use too much oil or let it into the tubing as wax contained in the oil will clog the capillary tubing 5 Service Parts for R404A some parts used for refrigerants other than R404A are similar to those for R404A But never use any parts unless they are specified for R404A because their endurance against the refrigerant have not been evaluated Also for R404A do not use any parts that have been used for other refrigerants Otherwise wax and chlorine remaining on the parts may adversely affect R404A 6 Replacement Copper Tubing R404A The copper tubes currently in use are suitable for R404A But do not use them if oily inside The residual oil in copper tubes should be as little as possible Low residual oil type copper tubes are used in the shipped units 33 7 Evacuation Vacuum Pump and Refrigerant Charge 404 Never allow the oil in the vacuum pump to flow backward The vacuum level and vacuum pump may be the same as those for th
30. timer which is factory set for normal conditions The timer has settings of 60 90 120 and 180 seconds 51 dip switch 1 amp 2 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 board for a complete harvest cycle is 2 minutes HWV is open during harvest for a maximum of 6 minutes or the length of harvest minus 0 10 30 or 50 seconds adjustable by 1 dip switch 7 amp 8 whichever is shorter LED 8 goes off when HWV closes PM energizes and runs for the last O 10 30 or 50 seconds of harvest depending on S1 dip switch 7 amp 8 setting LED 7 comes on when PM energizes At the end of harvest the control board checks the position of LF S and proceeds to the freeze cycle if it is closed or calls for a 1 minute fill if it is open c FREEZE CYCLE LEDs 5 amp 7 are on Comp continues to run PM and FMS energize HGV closes and the freeze cycle starts For the first 5 minutes after the thermistor temperature reaches 2 the control board will not accept a signal from LF S and UF S This minimum freeze period acts as a short cycle protection At the end of this period LF S and UF S assumes control As ice builds on the evaporator the water level in the sump lowers and LF S opens FWV opens LED 9 is on when FWV is open The refill will last until UF S closes or for 60 seconds whichever is shorter After UF S closes FWV closes 3 seconds later KM
31. to stabilize the circuit LEDs 4 through 8 energize and sequence from initial startup as listed in the table below Note that the order of the LEDs from the outer edge of the board is 5 6 8 9 4 7 For more information see 2 SEQUENCE OF OPERATION LED Energized Time LEDs are On Components Sequence Step 1 Minute Fill Cycle 8 60seconds _ Harvest Cycle 2 minutes 20 minutes 3 to 5 minutes Last 0 10 30 or 50 seconds adjustable by dip switch of harvest WV de energizes and PM energizes LEDs 5 and 7 are on 5 7 and Comp FMS _ freeze timer n Freeze Cycle 9 at refill E minutes setting 25 to 30 minutes Drain 9 6 4 7 10 seconds 20 seconds a a setting The built in safeties shut down the unit and have alarms as listed below pects Type of Alarm High Evaporator Temp Check for harvest problem stuck HGV or temperature gt 53 C relay hot water entering unit stuck HM or shorted thermistor Harvest Backup Timer Check for open thermistor HGV not harvest gt 20 min for tvoopening TXV leaking by low charge cycles in a row inefficient Comp or WRV leaking by Freeze Timer Check for a float switch stuck closed up freeze gt specified setting WV leaking by HGV leaking by PM not for two cycles in a row pumping T XV not feeding properly low Timer is factory set using charge or inefficient Comp 51 dip switch 9 amp 10 To reset the above safeties press t
32. 3 Recover the refrigerant and store it in an approved container 4 Remove the insulation and the expansion valve bulb on the suction line 5 Remove the expansion valve cover and disconnect the expansion valve Place the new expansion valve in position 6 Remove the drier then place the new drier in position 7 Braze all fittings while purging with nitrogen gas flowing at a pressure of 20 to 30 kPa 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 115 8 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 970 kPa DO NOT use R 404A as a mixture with pressurized air for leak testing 38 9 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the nameplate for the required refrigerant charge 10 Attach the expansion valve bulb to the suction line in the same location as the previous bulb The bulb should be at the 12 o clock position on the tube Be sure to secure the bulb with the clamp and holder and to insulate it 11 Place the expansion valve cover in position 12 Replace the panels in their correct positions 13 Turn on the power supply Always install a new Drier every time the sealed refrigeration system Is opened Do no
33. CE 5 50 b FUSE 50 c FUSE HOLDER ertaine e eE 50 d CONTROL BOARD ir entseina eenias 50 e MAGNETIC CONTACTOR 50 f CONTROL BOARD 5 50 9 STARTER 51 RUN CAPACITOR 51 i START 51 jl CAPACITOR FOR PUMP 51 19 SPRAY TUBE WATER SUPPLY TUBE SPRAY GUIDE 51 VI CLEANING AND MAINTENANCE INSTRUCTIONS 53 1 CLEANING seei 53 CLEANING 53 6 SANITIZING PROCEDURE 56 2 MAINTENANCE 56 a STAINLESS STEEL 57 6 STORAGE BIN AND 5 57 c AIR FILTER AIR COOLED MODEL ONLY 57 d CONDENSER AIR COOLED MODEL ONLY 57 3 PREPARING THE ICEMAKER FOR LONG STORAGE
34. D 201 refills 1 time After the refill the freeze continues until LF S opens again and terminates ice production d DRAIN CYCLE LEDs 4 5 6 and 7 are on Comp continues to run HGV opens FMS de energizes PM stops for 2 seconds DV energizes then restarts to take water from the sump and force it through DV and down the drain When the drain timer stops counting the drain is complete The drain timer is 10 or 20 seconds S1 dip switch 3 amp 4 Drain cycle always occurs on the 2nd harvest after startup Then depending on the control board setting drain cycle occurs every cycle or every 2nd 5th or 10th cycles S1 dip switch 5 amp 6 NORMAL HARVEST CYCLE LEDs 5 6 and 8 are on Comp continues to run HGV remains open and HWV opens As the evaporator warms the thermistor reaches 9 C The control board then receives the thermistors 3 9kO signal and starts the harvest timer HWV is open during harvest for a maximum of 6 minutes or the length harvest minus 0 10 30 or 50 seconds adjustable by 51 dip switch 7 amp 8 whichever is shorter LED 8 goes off when HWV closes PM energizes and runs for the last O 10 30 or 50 seconds of harvest depending on S1 dip switch 7 amp 8 setting LED 7 comes on when PM energizes At the end of harvest the control board checks for the position of LF S and proceeds to the freeze cycle if it is closed or calls for a 1 minute fill if it is open The unit continues to cycle through c d
35. Thermostatic Expansion Valve REFRIGERANT CHARGE R404A 520g ICE MAKING CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL SYSTEM Timer Controlled Overflow Pipe BIN CONTROL SYSTEM Mechanical Bin Switch ELECTRICAL PROTECTION Class Appliance 5A Fuse P C BOARD CIRCUIT PROTECTION High Voltage Cut out Internal COMPRESSOR PROTECTION Auto reset Overload Protector External REFRIGERANT CIRCUIT PROTECTION Auto reset High Pressure Control Switch LOW WATER PROTECTION Float Switch Net weight 57kg Gross weight 73kg PACKAGE Carton 668mm W X 727mm D X 793mm ACCESSORIES Instruction Manual Universal Brace Bolt 2 Power Cord SE type plug C101 BF type plug 111 O type plug C121 B3 type plug C131 A angle type plug C141 A parallel type plug C151 OPERATION CONDITIONS VOLTAGE RANGE 198 254V AMBIENT TEMP 7 40 C WATER SUPPLY TEMP 7 35 C WATER SUPPLY PRESS 0 7 7 8bar 0 07 0 78MPa We reserve the right to make changes in specifications and design without prior to notice b KMD 201 AWA water cooled AC SUPPLY VOLTAGE AMPERAGE STARTING AMPERAGE ELECTRICAL CONSUMPTION POWER FACTOR POWER SUPPLY CAPACITY ICE PRODUCTION PER 24h POTABLE WATER CONSUMPTION PER 24h CONDENSER WATER CONSUMPTION PER 24h SHAPE OF ICE FREEZE CYCLE TIME ICE PRODUCTION PER CYCLE DIMENSIONS EXTERIOR INSULATION CONNECTIONS ELECTRIC
36. anels 3 Disconnect the connector of the thermistor lead orange 4 Remove the ties insulation thermistor holder and thermistor in this order 47 5 Remove the old sealant from the thermistor holder and suction pipe 6 Wipe off any moisture or condensation from the suction pipe surfaces 7 Press a tube of the sealant KE 6ORTV manufactured by Shin Etsu Silicones to the recess of the thermistor holder Slowly squeeze the sealant out of the tube and spread it smoothly in the recess Do not use any sealant other than the above 8 Attach the new thermistor in position on the suction pipe and press down the thermistor holder over the thermistor Be careful not to damage the thermistor lead Cover the parts with the insulation and secure them with the ties Keep the thermistor inside the thermistor holder After the thermistor holder is fitted do not pull the thermistor lead to move the thermistor 9 Refit the removed parts in the reverse order of the removal procedure 10 Turn on the power supply Thermistor Lead Tie After Thermistor Holder is fitted do not pull Thermistor lead Insulation Thermistor Holder Fit right on top of pipe Fill up to slightly above top of recess Fill in shaded area Do not let in air and make a hollow in recess 18 CONTROL BOX 1 Turn off the power supply 2 Remove the front panel 3 Remove the one mounting screw and pull the control box cover 4 Remove the two mounting sc
37. cess Valve Strainer Hot Gas Valve Discharge Compressor Access Valve Pump Float Deflector Motor Switch Drain Thermistor Refrigerant Circuit EE Water Circuit Expansion Valve 22 2 WIRING DIAGRAM Id ot AJNAS 1214833 pec P00034 01 51 S p p I 01114 821 0 1 0 d 3070 18911 187 d AVE i9 Pow red 0 038 y wy 1g EHT a WOW ag 09 02 05 0 2 022 a The magnetic contactor wiring depends on the contactor model P00034 01 P01694 01 P00819 01 VC20 1a1b AC230V N 1A TUB G7L FC OTUL Teo 1 g E See above YOLIVINOD o ce b an an ud YOLIVINOD 23 EL e o o ul 99 06 8 9 Jaye 226 Sesues Jojsiuueu 3 19AO LS3AHVH 3 TIMING CHART ee 340 NO 2 zu Z 88 LL 2 2 LL LL zy 2 2 m
38. der high temperature and high humidity conditions may cause electric shock fire or corrosion to shorten the service life IMPORTANT Always install a new Drier every time the sealed refrigeration system 1 opened Do not replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply 2 Remove the panels and water tank See V 14 WATER TANK 35 3 Recover the refrigerant and store it in an approved container 4 Remove the terminal cover on the compressor and disconnect the compressor wiring 5 Remove the hold down bolts washers and rubber grommets 6 Remove the discharge and suction pipes 7 Remove the compressor Unpack the new compressor package 8 Attach the rubber grommets of the prior compressor 9 Place the compressor in position and secure it using the bolts and washers 10 Remove the drier then place the new drier in position 11 Remove plugs from the suction discharge and process pipes 12 Braze all fittings while purging with nitrogen gas flowing at a pressure of 20 to 30 kPa 13 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 970 kPa DO NOT use R 404A as a mixture with pressurized air for leak testing 14 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the
39. e current refrigerants However the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for R404A 8 Refrigerant Leak Check Refrigerant leaks can be detected by charging the unit with a little refrigerant raising the pressure with nitrogen and using an electronic detector Do not use air or oxygen instead of nitrogen for this purpose or rise in pressure as well as in temperature may cause R404A to suddenly react with oxygen and explode Be sure to use nitrogen to prevent explosion b REFRIGERANT RECOVERY The icemaker unit is provided with refrigerant access valve s Using proper refrigerant practices recover the refrigerant from the access valve s and store it in an approved container Do not discharge the refrigerant into the atmosphere c EVACUATION AND RECHARGE 1 Attach charging hoses a service manifold and a vacuum pump to the system 2 Turn on the vacuum pump 3 Allow the vacuum pump to pull down to a 760 mmHg vacuum Evacuating period depends on the pump capacity 4 Close the low side valve on the service manifold 5 Disconnect the vacuum pump and attach a refrigerant charging cylinder Remember to loosen the connection and purge the air from the hose See the nameplate for the required refrigerant charge 6 Open the low side valve Do not invert the charging cylinder A liquid charge will damage the compressor 7 Turn on the icemaker when charging speed get
40. e icemaker will be at sub freezing temperatures 1 On water cooled model only first remove the water from the water cooled condenser 1 Turn off the power supply and remove the front panel 57 2 Move the control switch on the control box to the OFF position 3 Wait 3 minutes 4 Move the control switch to the ICE position 5 Replace the front panel in its correct position and turn on the power supply 6 Allow 5 minutes for the icemaker to fill with water and the water pump to start operating 7 Close the condenser water supply line shut off valve 8 Open the condenser water supply line drain valve 9 Allow the line to drain by gravity 10 Attach compressed air or carbon dioxide supply to the condenser water supply line drain valve 11 Blow the condenser out using compressed air or carbon dioxide until water stops coming out 12 Close the condenser water supply line drain valve 2 Remove the water from the icemaker water supply line 1 Turn off the power supply and remove the front panel 2 Move the control switch on the control box to the OFF position 3 Close the icemaker water supply line shut off valve and open the icemaker water supply line drain valve 4 Allow the line to drain by gravity 5 Attach compressed air or carbon dioxide supply to the icemaker water supply line drain valve 6 Move the control switch to the ICE position 7 Replace the front panel in its correct position and t
41. e reservoir water 7 As water drains the float switch contacts should open Check continuity of the upper float switch contacts using the black and red wires and the lower float switch contacts using the black and blue wires With the float positioned all the way down both float switch contacts should be open If either float switch contact fails the assembly should be replaced 8 Reconnect the black connector to the control box when finished 6 BINCONTROL This machine uses lever actuated proximity switch mechanical bin control to control the ice level in the storage bin No adjustment is required a EXPLANATION OF OPERATION The bin control is connected to the K1 connector pins 4 amp 5 on the control board When the bin control is calling for ice proximity switch closed POWER OK LED on the control board continues icemaking operations When the bin control is activated in the bin full position proximity switch open POWER OK LED flashing the control board drains and shuts down the unit However to prevent incomplete batches of ice from forming on the evaporator the control board will only shut down the machine during the freeze cycle before the five minute timer expires The five minute timer starts counting down when the thermistor temperature reaches 2 C If during the freeze cycle ice pushes in the lever after the five minute timer expires the control board will allow the machine to complete the freeze cycle a
42. eck and replace and liquid line temperature too warm Check and get pressure too low or recommended pressure off and high pressure control opens and closes frequently Set too high Adjust or replace See V 9 Adjustment of Water Regulating Valve 6 EVAPORATOR IS FROZEN UP Problem Possible Cause 1 Freeze cycle time is a Float Switch 1 Leads short circuit 1 Check and replace too long defective switch 2 Float does not move 2 Clean or replace freely b Fill or Harvest Water 1 Diaphragm does 1 Check for water leaks with Valve close icemaker off Board Check Procedure g Expansion Valve 1 Operating erratically I AIrice formed on evaporator does py Water Supply Line 1 Water pressure too 1 Check and get fall into bin in harvest low recommended pressure cycle Water Filter system 1 Dirty Restricted 1 Replace filter orifice 2 Check for water leaks with icemaker off 2 Diaphragm does not close e Ambient and or water 1 Too cool temperature f Line Valve 1 Continues to open in if applicable g Thermistor Increase temperature Check operation in harvest cycle and replace See V 17 Thermistor harvest cycle 1 Out of position or loose attachment 1 Harvest timer is set too short h Control Board See Il 3 c Controls and Adjustments b Harvest Timer 30 Problem Possible Cause
43. er 2 5 or earlier Must remain off j Anti Slush Control S2 dip switch 6 Program Ver 2 5 or earlier The anti slush control Ver 1 0 helps prevent slushing during the freeze cycle on small icemakers It is deactivated on the KMD 201 series When activated the thermistor located on the suction line checks for a 34 F 1 C temperature as the evaporator cools When 34 F 1 C is reached a 5 9 signal causes the control board to de energize the pump motor for 10 seconds Do not adjust This must be left in the factory default position or the unit will not operate properly 52 Dip Switch Setting Anti Slush Control No 6 6 2 Activated Ver 1 0 Deactivated Control Board P01771 02 k Harvest Promotion Control S2 dip switch 2 Program Ver 3 1 Ver 3 2 Do not adjust This must be left in the factory default position or the unit will not operate properly It is deactivated on the KMD 201 series When activated this control promotes harvest of ice on the evaporator that is hard to remove If the harvest cycle exceeds 6 minutes the pump motor starts to operate for maximum of 3 minutes 52 Dip Switch Setting Harvest Promotion No2 o Control Activated Deactivated I Refill Counter S2 dip switch Program Ver 3 1 Ver 3 2 Do not adjust This must be left in the factory default position or the unit will not operate properly The KMD 201AA and KMD 201AWA refill 1 time m Harvest Com
44. f water 2 Remove the front insulation 3 Pour the sanitizing solution into the water tank 4 Move the service switch to the WASH position 5 Replace the front insulation and the front panel in their correct positions 6 Turn on the power supply to start the sanitizing process 7 Turn off the power supply after 15 minutes 8 Remove the front panel 9 Move the service switch to the DRAIN position 10 Replace the front panel in its correct position and turn on the power supply for 2 minutes 11 Turn off the power supply 12 Remove the front panel 13 Repeat steps 18 through 31 in a CLEANING PROCEDURE two times to rinse thoroughly 14 Move the control switch to the ICE position 15 Replace the front panel in its correct position 16 Clean the storage bin dispenser unit liner using a neutral cleaner Rinse thoroughly after cleaning 17 Turn on the power supply to start the automatic icemaking process 2 MAINTENANCE IMPORTANT This icemaker must be maintained individually referring to the instruction manual and labels provided with the icemaker 56 STAINLESS STEEL EXTERIOR To prevent corrosion wipe the exterior occasionally with a clean soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up b STORAGE BIN AND SCOOP Wash your hands before removing ice Use the plastic scoop provided bin accessory The storage bin dispenser unit is for ice use o
45. fter any maintenance or cleaning is done to the equipment 1 CLEANING 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 Carefully follow any instructions provided with the bottles of cleaning and sanitizing solution 4 Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin 5 To prevent damage to the water pump do not leave the control switch in the SERVICE position for extended periods of time when the water tank is empty a CLEANING PROCEDURE 1 Dilute approximately 9 5 fl oz 281 ml of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 1 8 gallon 6 8 lit of water 2 Remove all ice from the evaporator and the storage bin dispenser unit Note To remove cubes on the evaporator turn off the power supply 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 move the control switch to the SERVICE position Move the service switch to the DRAIN position 5 Replace the front panel in its correct position and turn on the power supply for 2 minutes 6 Turn off the power supply 53
46. gnal 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 harvest water valve still open Average harvest cycle at factory setting is 2 to 4 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 The compressor remains energized pump motor line valve if applicable and fan motor energize The harvest water valve and hot gas valve de energize The unit is held in freeze by a 5 minute short cycle protection timer which starts after the thermistor temperature reaches 2 C After this period the freeze cycle operation is transferred to the float switch for freeze termination The lower float switch activates open 2 times during the course of a freeze cycle the first is for refill the second is for freeze termination After the second lower float switch activation the control board terminates freeze and initiates harvest 25 a Lower Float Switch 1st Activation Ref
47. h 6 Route the bin control lead through the hole in the base then into the bushing provided Bin Control Lead Bushing 7 While pulling up the bin control lead hook the bin control on the right side interior wall Then push the bin control up against the bottom of the unit and slide to the back until it Snaps in place Make sure the slotted holes at the right side of the bin control are securely placed on the collars at the bottom of the unit 46 CAUTION Make sure the bin control is securely in place Otherwise ice may get between gaps and damage the bin control Bin Control 8 Pull up any slack in the bin control lead then put the bushing attached to the bin control lead back into the hole in the base 9 Connect the bin control connector to the side of the control box 10 Replace the water tank cube guide pump motor bracket pump motor and float switch in their correct positions until they snap in place CAUTION Be sure to let the discharge hose pass behind the copper tube and connect it securely in position Otherwise the discharge hose may be caught in the front insulation leading to improper results 11 Secure the pump motor bracket with the two thumbscrews 12 Reconnect the pump motor connector and float switch connector 13 Replace the front insulation and front panel in their correct positions 14 Turn on the power supply 17 THERMISTOR 1 Turn off the power supply 2 Remove the p
48. he ALARM RESET button with the power supply High Voltage The control voltage safeties automaticlly 294Vac x 596 or more reset when voltage is corrected Legend Comp compressor DV drain valve FMS self contained fan motor FWV fill water valve HGV hot gas valve HM headmaster HWV harvest water valve WRV water regulating valve PM pump motor TXV thermostatic expansion valve on Voltage POWER OK LED will turn off if voltage 184Vac 5 or less protection operates 11 CONTROLS AND ADJUSTMENTS a Default Dip Switch Settings The dip switch is factory adjusted to the following positions 51 SwitthNo 1 2 3 4 5 6 7 8 9 10 ON 51 Dip Switch 52 Dip Switch Freeze Timer 9 amp 10 gt gt Water Saver Timer 7 amp 8 Drain Frequency Control 5 amp 6 Drain Timer 3 amp 4 Harvest Timer 1 amp 2 Functions of S2 dip switch nos 2 through 6 depend on program version Contro Board Program ver 62 SwitchNo 1 2 3 4 8 6 nd OFF Do not adjust the S2 dip switch These must be left in the factory default position or the unit will not operate properly b Harvest Timer 51 dip switch 1 amp 2 Used for adjustment of the harvest timer The harvest timer starts counting when the thermistor reads a certain temperature at the evaporator outlet Dip Switch Setting Time seconds
49. he Drier until after all other repair or replacement has been made 1 Turn off the power supply 2 Remove the panels 3 Close the condenser water supply line shut off valve then open the condenser water supply line drain valve 4 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve 5 Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 6 Recover the refrigerant and store it in an approved container 7 Disconnect the capillary tube at the condenser outlet 8 Disconnect the flare connections of the valve 9 Remove the screws and the valve from the bracket 10 Install the new valve 11 Remove the drier then place the new drier in position 12 Braze all fittings while purging with nitrogen gas flowing at a pressure of 20 to 30 kPa 13 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 970 kPa DO NOT use R 404A as a mixture with pressurized air for leak testing 14 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 15 Connect the flare connections 16 Close the condenser water supp
50. he hot gas circuit 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 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Disconnect the hot gas valve leads 5 Remove the screw and the solenoid coil 6 Remove the valve and drier using brazing equipment 7 Braze the new hot gas valve with nitrogen gas flowing at a pressure of 20 to 30 kPa 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 135 C 3 8 Install the new drier see V 4 DRIER 9 Check for leaks using nitrogen gas 970 kPa and soap bubbles 10 Evacuate the system and charge it with refrigerant see V 1 EVACUATION AND RECHARGE 11 Attach the solenoid coil to the valve body and secure it with the screw 12 Connect the lead wires 13 Refit the panels in their correct positions 14 Turn on the power supply 6 EXPANSION VALVE IMPORTANT The water in the refrigeration circuit may exceed the capacity of the Drier and freeze in 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 2 Remove the panels
51. ill The refill can occur at any time during the freeze cycle 1 refill per cycle As ice builds the water level drops in the reservoir and the lower float switch activates opens LED 5 comes on and the control board energizes the fill water valve The fill water valve remains energized until the upper float switch closes or the 1 minute fill timer terminates whichever comes first b Lower Float Switch 2nd Activation The unit is held in freeze by a 5 minute short cycle protection timer which starts after the thermistor temperature reaches 2 After the 1st lower float switch activation and refill ice continues to form and the water level drops in the reservoir When the lower float switch activates opens a second time the freeze cycle terminates freeze can only be terminated on the second activation of the lower float switch and after the minimum freeze period Diagnosis During the minimum freeze period confirm that the evaporator temperature drops compressor fan motors and pump motor are energized and that the hot gas valves harvest water valve and fill water valve except during refill are de energized and not bypassing Make sure the expansion valves are operating properly and in cold conditions Make sure that the drain water valve is not leaking by water flowing down the potable drain Check for proper unit pressures or an inoperative compressor Disconnect the 3 pin float switch connector from the control box 15 seconds af
52. itch closes When the float switch closes the control board changes to the next cycle The unit will not start without adequate water in the sump This serves as a low water safety to protect the water pump For water cooled model if the condenser water supply is shut off the unit is protected by the high pressure switch e High Voltage and Low Voltage Cut outs The maximum and minimum allowable supply voltages of this icemaker are limited by the high voltage and low voltage cut outs If miswiring especially on single 3 phase wire models causes excessive voltage 294 Vac 5 or more on the control board the high voltage cut out shuts down the circuit in 3 seconds and the icemaker automatically stops The control board will signal this problem using 7 beeps every 3 seconds The icemaker also automatically stops in cases of insufficient voltage 184Vac x 5 or less The control board will signal this problem using 6 beeps every 3 seconds When the proper supply voltage is resumed the icemaker automatically starts running again f LED Lights and Audible Alarm Safeties The control board includes LED indicator lights audible alarm safeties and an output test feature The POWER LED indicates control voltage and will remain on unless a control voltage problem occurs The POWER OK LED flashes continuously when the bin is full and DV energizes for a maximum of 5 minutes to drain the water tank At startup a 5 second delay occurs
53. ly line drain valve then open the condenser water supply line shut off valve 40 17 Check for water leaks 18 Replace the panels in their correct positions 19 Turn on the power supply 9 ADJUSTMENT OF WATER REGULATING VALVE WATER COOLED MODEL ONLY The water regulating valve also called water regulator is factory adjusted No adjustment is required under normal use Adjust the water regulator if necessary using the following procedures 1 Prepare a thermometer to check the condenser drain temperature Attach a pressure gauge to the high side line of the system 2 Five minutes after a freeze cycle starts confirm that the thermometer reads 40 C to 46 C If it does not rotate the adjustment screw by using a flat blade screwdriver until the temperature is in the proper range See Fig below Next check that the reference pressure is in the range indicated in the Head Pressure table in the Performance Data section If it is not in the proper range verify the refrigerant charge 3 Check that the condenser drain temperature is stable Adjustment Screw CW Higher CCW Lower 10 FAN MOTOR 1 Turn off the power supply 2 Remove the panels 3 Loosen the two screws securing the fan blade cover then remove it 4 Disconnect the connector of the fan motor lead 5 Loosen the far side of the two screws and remove the near side of the two screws securing the fan motor bracket and slide out towards you
54. me Front Galvanized Steel Rear Polyurethane Foam X type Connection Inlet 1 2 FPT Cond Inlet 1 2 FPT connected at rear side Outlet 3 4 FPT Cond Outlet 1 2 FPT connected at rear side AT 21 C WT 15 C AT 32 C WT 21 C Hermetic 560W Model NT6217GK Water cooled Tube in Tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R404A 400g Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe Mechanical Bin Switch Class Appliance 5A Fuse High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch Net weight 58kg Gross weight 74kg Carton 668mm W X 727mm D X 793mm Instruction Manual Universal Brace Bolt 2 Power Cord SE type plug C101 BF type plug 111 O type plug C121 B3 type plug C131 A angle type plug C141 A parallel type plug C151 198 254V 7 40 C 7 35 C 0 7 7 8bar 0 07 0 78MPa ll GENERAL INFORMATION 1 CONSTRUCTION a KMD 201AA Water Supply Tube Drain Valve Spray Guide Water Supply Inlet Spray Tube Hot Gas Valve Access Valve i High Side Not provided for later production Condenser Thermistor _ Expansion Valve Access Valve Low Side Fan Motor Compressor Cube Guide Water Tank Pump Motor Control Box Float Switch Harvest Water Valve Fill Water Valve C
55. nd the following harvest cycle before shutting down the machine 6 BIN CONTROL CHECK PROCEDURE 1 Clear any ice away from the bin control 2 Make sure the control switch is in the ICE position 3 Check that the POWER OK LED on the control board is on 4 Activate the bin control actuator press the actuator in Check that the POWER OK LED flashes 5 Disconnect the bin control at the 2 pin connector attached to the black wires coming from the K1 connector pins 4 amp 5 on the control board 6 Check for continuity across the bin control leads When calling for ice the bin control proximity switch should be closed If open replace the bin control Activate the bin control actuator press the actuator in check for continuity across the bin control leads The bin control proximity switch should be open If closed replace the bin control 7 Reconnect the 2 pin connector Allow the machine to cycle into the freeze cycle In the first 5 minutes of the freeze cycle activate the bin control actuator press the actuator in The POWER OK LED should flash and the machine should turn off If not replace the control board 20 7 SWITCHES Two different control switches are used for operation of KMD 201AA and KMD 201AWA These switches are referred to as the control switch and the service switch and are located on the control box a CONTROL SWITCH This switch is used to place the machine into one of three modes
56. nly Do not store anything else in the storage bin dispenser unit Clean the scoop and the storage bin dispenser unit liner using a neutral cleaner Rinse thoroughly after cleaning c AIR FILTERS AIR COOLED MODEL ONLY Plastic mesh air filters remove dirt and dust from the air and keep the condenser from getting clogged As the filters get clogged the icemaker s performance will be reduced Check the filters at least twice a month When clogged use warm water and a neutral cleaner to wash the filters d CONDENSER AIR COOLED MODEL ONLY 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 3 PREPARING THE ICEMAKER FOR LONG STORAGE CAUTION 1 When shutting off the icemaker for an extended time drain out all water from the water line and remove the ice from the storage bin dispenser unit The storage bin dispenser unit 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 2 o prevent damage to the water pump do not leave the control switch in the SERVICE position for extended periods of time when the water tank Is empty 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 th
57. omplete The control board will signal this problem using 2 beeps every 3 seconds The freeze timer shuts down the icemaker if for two cycles in a row the freeze cycle takes longer than the time specified to complete The control board will signal this problem using 3 beeps every 3 seconds The time is factory set using S1 dip switch 9 amp 10 The alarm reset button on the control board must be pressed with power on to reset either of these safeties c High Temperature Safety The temperature of the suction line in the refrigeration circuit is limited by the high temperature safety This protects the unit from excessively high temperatures If the evaporator temperature rises above 53 4 C the thermistor operates the safety This shuts down the circuit and the icemaker automatically stops The control board will signal this problem using 1 beep every 3 seconds The alarm reset button on the control board must be pressed with power on to reset the safety d Low Water Safety The control board checks the position of the lower float switch at the end of the initial one minute water fill cycle and at the end of each harvest cycle If the lower float switch is in the up position electrical circuit closed the control board changes to the next cycle If the lower float switch is in the down position electrical circuit open the control board changes to additional one minute water fill cycles until water enters the sump and the float sw
58. ons 12 Turn on the power supply to start the washing process 13 Turn off the power supply after 30 minutes 14 Remove the front panel 15 Move the service switch to the DRAIN position 16 Replace the front panel in its correct position and turn on the power supply for 2 minutes 17 Turn off the power supply and remove the front panel 18 Move the control switch to the ICE position 19 Replace the front panel in its correct position 20 Turn on the power supply to fill the water tank with water 21 Turn off the power supply after 3 minutes 22 Remove the front panel 23 Move the control switch to the SERVICE position Move the service switch to the WASH position 24 Replace the front panel in its correct position 25 Turn on the power supply to rinse off the cleaning solution 26 Turn off the power supply after 5 minutes 27 Remove the front panel 28 Move the service switch to the DRAIN position 29 Replace the front panel in its correct position and turn on the power supply for 2 minutes 30 Turn off the power supply 55 31 Remove the front panel 32 Repeat steps 18 through 31 three more times to rinse thoroughly Note If you do not sanitize the icemaker go to step 14 in Sanitizing Procedure b SANITIZING PROCEDURE FOLLOWING CLEANING PROCEDURE 1 Dilute a 5 25 sodium hypochlorite solution chlorine bleach with water add approximately 0 9 fl oz 27 ml to 1 8 gal 6 8 lit o
59. ontrol Switch Service Switch Fuse Holder Fuse Drier Bin Control Switch b KMD 201AWA Water Supply Tube Drain Valve Spray Guide Water Supply Inlet Spray Tube Hot Gas Valve Access Valve __ High Side ic Not provided for later production Water Regulator Thermistor Expansion Valve Access Valve Low Side Condenser Compressor Cube Guide Drier Water Tank Pump Motor Control Box Float Switch Harvest Water Valve Fill Water Valve Control Switch Service Switch Fuse Holder Fuse Bin Control Switch 2 SEQUENCE OF OPERATION 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 board is 5 6 8 9 4 7 a ONE MINUTE FILL CYCLE LED 8 is on HWV opens and the fill period begins After 1 minute the board checks for a closed LF S If LF S is closed the harvest cycle begins If not HWV will remain energized through additional 1 minute cycles until water enters the sump and LF S closes This serves as a low water safety to protect the water pump b INITIAL HARVEST CYCLE LEDs 5 6 and 8 are on HWV remains open Comp energizes HGV opens and harvest begins As the evaporator warms the thermistor located on the suction line checks for a 9 C temperature When 9 C is reached a 3 9 kQ signal turns the harvest over to the adjustable harvest
60. ounting located on the suction line next to the evaporator outlet Temperature F Temperature Resistance 2 18 14 401 10 613 2 0 6 000 3 871 2 474 9 332 1 633 Check a thermistor for resistance by using the following procedure 1 Disconnect the thermistor orange wires at the 2 pin connector on the control box See Fig below 2 Remove the thermistor See V 17 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 kO Replace the thermistor if it exceeds the normal reading Thermistor Connector orange wires Bin Control Wires black Float Switch Connector red wires 5 FLOAT SWITCH a EXPLANATION OF OPERATION The float operates 2 switches within the float switch The lower switch black and blue wires is used for low water safety protection initiating the freeze cycle refill and terminating the freeze cycle The upper switch black and red wires is used to terminate the freeze cycle refill only Refill will last until the upper float switch closes or the 1 minute countdown timer ends whichever comes first b CLEANING Depending on local water conditions scale may build up on the float float switch shaft and inside the housing Scale on the float or shaft can cause the float to stick causing erratic operation The float
61. pacitor 2 Install the new run capacitor in the reverse order of the removal procedure 3 To prevent miswiring check the terminal numbers and lead wire colors with the wiring label CAPACITOR FOR PUMP MOTOR 1 Disconnect the tab terminals remove the screw 2 Install the new capacitor in the reverse order of the removal procedure 19 SPRAY TUBE WATER SUPPLY TUBE SPRAY GUIDE 1 Turn off the power supply 2 Remove the panels and front insulation 3 Remove the hose band connecting the hose 4 Push the tabs on both sides of the spray tube to release the spray tube 5 Pull the spray tube towards you 51 Hose Band Water Supply Tube under Spray Tube Spray Tube Hose Hose Band 6 The spray tube is easily cleanable by removing the black rubber caps on the ends 7 Remove the hose band connecting the water supply tube 8 Pull the water supply tube towards you 9 Remove the top insulation 10 The spray guide is located under the water supply tube Pull off the spray guide from the evaporator Spray Guide 11 Refit the removed parts in the reverse order of the removal procedure Check for water leaks IMPORTANT Fit the spray guide securely and tightly on the evaporator fin Otherwise cloudy or irregular ice cubes or performance reduction may be caused 52 VI CLEANING AND MAINTENANCE INSTRUCTIONS IMPORTANT Ensure all components fasteners and thumbscrews are securely in place a
62. pletion Detection Control S2 dip switch 4 Program Ver 3 1 Ver 3 2 Do not adjust This must be left in the factory default position or the unit will not operate properly It is deactivated on the KMD 201 series When activated this control determines whether ice remains on the evaporator at the end of a harvest cycle and at the beginning of a freeze cycle If ice drops and activates the bin control switch in the last 10 seconds of a harvest cycle the control determines that ice still remains on the evaporator and extends the harvest cycle for 30 seconds If the bin control switch is activated at the beginning of a freeze cycle the control determines that ice still remains on the evaporator and starts a harvest cycle after the minimum freeze cycle time has passed 52 Dip Switch Setting Harvest Completion No 4 Detection Control Deactivated Activated n Overfreeze Detection Control S2 dip switch 5 Program Ver 3 1 Ver 3 2 Do not adjust This must be left in the factory default position or the unit will not operate properly It is deactivated on the KMD 201 series When activated the thermistor detects the temperature of the evaporator outlet to find overfreeze in a harvest cycle and at the beginning of a freeze cycle If the difference between the maximum temperature after the water saver timer starts counting and the 15 temperature at the end of a harvest cycle is 4K or more if the temperature at the end
63. r FMS FMS off when LED on Connector K3 Magnetic Contactor Connector K4 Open LED 8 X4 Relay Inlet Water Valve WV Harvest Water Valve HWV on units with two inlet water valves POWER OK LED Lights when power is supplied to the board Flashes when bin control is activated Sn M LED 9 X5 Relay Connector K5 Freeze Water Valve Pins FWV on units with 1 Fan Motor two inlet water valves 2 Hot Gas Valve 3 Pump Motor 4 Harvest Water Valve 5 Freeze Water Valve 6 Drain Valve LED 4 X6 Relay Drain Valve DV LED 7 X3 Relay Connector K6 Pump Motor PM Open Connector K8 Connector K1 Open Pins Output Test Button 5 a Tu DW used to test relays on 1 2 3 Float Switch 4 5 Bin Control boardi 6 7 Thermistor 999099506 e 8 9 K2 Alarm Buzzer 51 Dip Switch 52 Dip Switch Alarm Reset Button Control Board Auxiliary Code V1 or Earlier V2 or Later Part Number P00013 02 P01771 02 HKM2006V003 6 FEATURES a Maximum Water Supply Period 6 minutes The harvest water valve will be open during harvest for 6 minutes or the length of harvest minus O 10 30 or 50 seconds adjustable by S dip switch 7 amp 8 whichever is shorter b Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if for two cycles in a row the harvest cycle takes more than 20 minutes to c
64. rews and pivot the control box to the left side slightly and pull the control box towards you if needed 5 Refit the removed parts in the reverse order of the removal procedure 48 Screws Control Box Cover Screw Control Box Note After replacing the components inside the control box connect and tie the wires properly in their correct position Especially make sure that the harness does not press the push buttons on the control board Controller Board Control Switch i Service Switch Nn c Noise Suppression Capacitor Fuse Fuse Holder Push Buttons Transformer Starter Run Capacitor Capacitor for Pump Motor Start Capacitor Magnetic Contactor 49 a CONTROL amp SERVICE SWITCH 1 Disconnect the tab terminals and remove the nut securing the power switch 2 Install the new switch in the reverse order of the removal procedure 3 To prevent miswiring check the terminal numbers and lead wire colors with the wiring label b FUSE 1 Use a phillips head screwdriver to remove the fuse holder cap and take out the fuse 2 Install the new fuse in the reverse order of the removal procedure c FUSE HOLDER 1 Disconnect the tab terminal and remove the nut securing the fuse holder 2 Install the new fuse holder in the reverse order of the removal procedure d CONTROL BOARD 1 Disconnect all the connectors 2 Remove the four board supports secured to the control box to release the
65. ry 2 5 or 10 cycles The factory default is every 10 cycles The unit always restarts at the 1 minute fill cycle 26 2 DIAGNOSTIC CHARTS a NO ICE PRODUCTION Problem Possible Cause 1 The icemaker will not a Power Supply 1 Off blown fuse or 1 Turn on replace or reset tripped breaker 3 Bad contacts 3 Check for continuity and replace 4 Not within specifications b Water Supply 1 Water supply off or pressure too low 4 Hefer to nameplate and correct 1 Check and get recommended pressure c Fuse Control Box 1 Blown 1 Check for short circuit and replace 1 OFF or SERVICE 1 Move to ICE position position d Control Switch 2 Bad contacts 2 Check for continuity and replace 1 Tripped with bin filled 1 Remove ice with ice 2 Defective 2 See Il 6 b Bin Control Check Procedure f 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 a 7 except water cooled model e Bin Control 6 Refrigerant line or 6 Clean and replace drier components plugged 7 Condenser water 7 Check and get pressure too low or recommended pressure off water cooled model g Transformer 1 Coil winding opened
66. s slow Turn off the icemaker when the low side gauge shows approximately 0 kg cm Do not run the icemaker at vacuum pressures Close the low side valve when the charging cylinder gets empty 8 Repeat steps 4 through 7 if necessary until the required amount of refrigerant has entered the system 9 Close the refrigerant access valve s and disconnect the hoses service manifold etc 10 Cap the access valve s to prevent possible leak 34 Depressed Cap Access Valve OPEN 2 BRAZING DANGER 1 Refrigerant R404A itself is not explosive or poisonous However when exposed to high temperatures open flames R404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous 2 Always recover the refrigerant and store it in a proper container Do not discharge the refrigerant into the atmosphere 3 Do not use silver alloy or copper alloy containing Arsenic 4 Do not use R404A 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 Note All brazing connections inside the bin are clear coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove the coating 3 COMPRESSOR WARNING The Compressor Terminal Cover must be refitted in its correct position Otherwise operation un
67. t replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply 2 Remove the panels and the front and top insulation 3 Recover the refrigerant and store it in an approved container 4 Remove the spray tubes Remove the insulation at the U shaped notch where the refrigeration tubing passes through the molded chassis 5 Disconnect the evaporator tubing 6 Remove the pop rivets securing the evaporator then lift out the evaporator 7 Install the new evaporator 8 Remove the drier then place the new drier in position 9 Braze all fittings while purging with nitrogen gas flowing at a pressure of 20 to 30 kPa 10 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 970 kPa DO NOT use R 404A as a mixture with pressurized air for leak testing 11 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the nameplate for the required refrigerant charge 12 Replace the removed parts in the reverse order of which they were removed 13 Replace the insulation and the panels in their correct positions 39 14 Turn on the power supply 8 WATER REGULATING VALVE WATER COOLED MODEL ONLY IMPORTANT Always install a new Drier every time the sealed refrigeration system 1 opened Do not replace t
68. ter disconnecting the 3 pin float switch connector LED 5 comes on and refill begins Connect the 3 pin float switch connector back on the control box When the refill is finished LED 5 goes off disconnect the 3 pin float switch connector again If 5 or more minutes have elapsed in the freeze cycle the unit should switch out of the freeze cycle After the unit switches out of freeze reconnect the 3 pin float switch connector to the control box If the unit remains in freeze with the float switch disconnected replace the board To check the float switch see Il 5 c FLOAT SWITCH CHECK PROCEDURE 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 Drain Cycle The compressor remains energized the hot gas valve energizes the fan motor de energizes The drain valve and pump motor energize allowing water to drain from the tank for 20 seconds This removes contaminants from the water tank Diagnosis If the drain valve does not open check the circuit Check for proper voltage If water does not drain out check and clean the tubing at the drain valve and then check and 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 turned off The drain cycle can be adjusted to occur every cycle or eve
69. tic 1 Clean or replace operation c Control Board 1 Defective 1 See Il 3 d Control Board Check Procedure a Fan Motor 1 Motor winding 1 Replace opened 2 Bearing worn out 2 Replace 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 b Control Board 1 Defective 1 See Il 3 d Control Board Check Procedure a Refrigerant 1 Low charge 1 Check for leaks and recharge 2 Air or moisture 2 Replace drier and trapped recharge b Compressor 1 Defective valve 1 Replace c Hot Gas Valve 1 Continues to open 1 Check and replace freeze cycle d Line Valve 1 Continues to close in 1 Check and replace 7 Fan motor will not start or is not operating except water cooled model 8 All components run but no ice is produced if applicable freeze cycle 29 Problem Possible Cause 1 Water valve is wide open during freeze 8 All components e Fill or Harvest Water run but no ice is Valve produced continued f Expansion Valve 9 Headmaster C P H remote air cooled model only h Water Supply Line water cooled model only i Water Regulating Valve 1 water cooled model only Operating erratically Not operating properly 1 Replace headmaster Condenser water 1 Check for water leaks with icemaker off Ch
70. urn on the power supply 8 Blow the icemaker water supply line out using compressed air or carbon dioxide 3 Drain the water tank 1 Turn off the power supply and remove the front panel 2 Move the control switch to the SERVICE position and move the service switch to the DRAIN position 3 Replace the front panel in its correct position and turn on the power supply for 2 minutes 58 4 Turn off the power supply and remove the front panel 5 Move the control switch to the OFF position 6 Replace the front panel in its correct position 7 Remove all ice from the storage bin dispenser unit and clean the storage bin dispenser unit 8 Close the icemaker water supply line drain valve 59
71. ve the service switch to the DRAIN position 4 Let the icemaker run for 2 minutes 5 Move the control switch to the OFF position 6 Turn off the power supply 7 Disconnect the pump motor and float switch connector from the side of the control box 8 While pushing up the snap tab at the right side of the pump motor bracket pull out the water tank cube guide pump motor bracket pump motor and float switch together 44 17 o 0 Pump Mot ump Motor Float Switch q Cube Guide Snap 9 Install the new water tank in the reverse order of the removal procedure 10 Refit the panels in their correct positions 11 Turn on the power supply 15 FLOAT SWITCH 1 Remove the pump motor bracket See V 14 WATER TANK 2 Pull up the pump motor bracket from the water tank 3 Flip over the pump motor bracket assembly then twist off the float switch and pull out towards you 4 Install the new float switch in the reverse order of the removal procedure 5 Refit the panels in their correct positions 6 Turn on the power supply 16 BINCONTROL SWITCH 1 Remove the water tank See V 14 WATER TANK 2 Disconnect the connector of the bin control switch lead black 3 Pull out the bin control switch tab outside and slide the bin control switch towards you Bin Control Switch Tab 4 Take out the bin control 5 Install the new bin control switc

KMD-201AA SERVICE MANUAL

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