KML-400M_E Service Manual
Contents
1. 39 12 REMOVAL AND REPLACEMENT OF WATER VALVE 40 13 REMOVAL AND REPLACEMENT OF PUMP eem 40 14 REMOVAL AND REPLACEMENT OF SPRAY 41 CLEANING AND MAINTENANCE INSTRUCTIONS 42 1 PREPARING THE ICEMAKER FOR LONG 5 22 2 42 22 DUC E 44 a a 46 As MAINTENANCE o abri edipi devia Ba pa 47 iii A1BAA0219807 SPECIFICATIONS 1 400 AC SUPPLY VOLTAGE 115 60 1 AMPERAGE 13 3 5 MIN Freeze AT 104 F WT 80 F MINIMUM CIRCUIT AMPACITY 20A MAXIMUM FUSE SIZE 20A APPROX ICE PRODUCTION Ambient PER 24 HR Ibs day kg day 70 410 186 360 164 305 139 Reference without marks 80 390 177 340 155 290 132 90 375 170 325 148 275 125 100 360 164 310 141 255 116 SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 6 6 Ibs 3 0 kg 360 pcs APPROXIMATE STORAGE CAPACITY N A ELECTRIC amp WATER CONSUMPTION 90 70 70 F 50 F ELECTRIC W KWH 100 lbs 1190 8 7 1110 6 6 WATER gal 24 HR gal 100 Ibs 140 41 290 70 EXTERIOR DIMENSIONS WxDxH 30 x 2788 x 22 762 x 695 x 560 mm EXTERIOR FINISH Stainless steel Galvanize2. 00 4 19 1 0219801 3 TIMING CHART When Control Sw is turned OFF Pressure Sw is OFF or Thermistor Temp exceeds tl From Defrost Cycle To Defrost Cycle If Float Sw is OFF Mid Temp Lo Temp Too Lo Temp Hi Temp Water Initial Defrost Froeze t1 Thermistor t2 Temp t3 ON Float Switch Compressor 85 Control Sw in ICE Icemaking li Pump Motor SERE SON Pressure Fan Motor ON amp Line Valve or Fan Motor en Condenser Unit or Water Valve Hot Gas Valve NOTE The icemaker does not complete a defrost cycle in the first 2 or minutes See Il 2 d CONTROLS AND ADJUSTMENTS 20 A1BAA0219801 m Stand by Cycle When Control Sw is turned OFF Pressure Sw is OFF or Thermistor Temp exceeds tl Freeze Cycle From Freeze Cycle 1 2 A1BAA0219801 High Temp Mid Temp Low Temp Too Low Temp Modes Mode f Defrost include drain Wash 1 Thermistor t Temp t 2 3 ON Float Switch Wi or LI LI ON Compressor OFF Heater 1 Sw in Pump Motor 1 amp Line Valve SINE A Fan Motor on Condenser Unit on Water Valve 2 L I ON Hot Gas Valve 2
3. AMBIENT TEMP 70 100 100 105 80 99 105 105 90 99 105 105 100 100 105 105 37 A1BAA0219807 10 REMOVAL AND REPLACEMENT OF THERMISTOR CAUTION Fragile handle very carefully Always use a recommended sealant High Thermal Conductive Type Model KE4560RTV manufactured by SHINETSU SILICONE Part Code 60Y000 11 or Part Code 4A0683 01 or equivalent Always use a recommended foam insulation Non absorbent Type or equivalent 4 Do not shorten or cut the Thermistor leads when installing it 1 Turn off the power supply Thermistor Lead Cable Tie 2 Remove the panels 3 Remove the Control Box Cover zu 217272 fi 4 Disconnect the Thermistor leads from the K3 Connector on the Controller Board SS 5 Remove the Plastic Cable Ties Foam Insulation Thermistor Holder and Thermistor See Fig 2 Foam Insulation Thermistor Holder Fig 2 6 Scrape away the old sealant on the Thermistor Holder and the Suction Pipe 7 Wipe off moisture or condensation on the Suction Pipe 8 Smoothly apply recommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the Thermistor Holder concave 9 Attach the new Thermistor to the Suction Pipe very carefully to prevent damage to the leads And secure it using the Thermistor Holder and recommended foam insulation 38 A1BAA0219807 10 Secure the insulation using the Plastic Cable Ties 11 Connect
4. 1 2 KML 400MWE Water cooled 2 5 55 a ce ORSIDROR dok on Recta tutt 3 T CONSTRU O rre hn pce Herb td ae Reb an dd estan ASA GARS eR 3 a KML 400MAE Air cooled 3 b KML 400MWE Water cooled eene nnns 4 25 CONTROLLER BOARD irene a p a a B 5 a SOLID STATE CONTROL B 5 b CONTROLLER BOARD ROME DEDERE Xu 5 lc SEQUENCE ou tase aw on Mta aao ed ab po CEU UL etn RE RR 8 d CONTROLS AND 11 e CHECKING CONTROLLER 14 Ba OVA T ne tok iati 16 TECHNICAL INFORMATION Las S Ca EY 17 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 17 a KML 400MAE Air cooled uo 17 D KML 400MWE Water cooled IIR Ia 18 2 AWIBINGSDIAGBAMS we 19 a KML 400MAE Air cooled ee Fare 19 b KML 400MWE Water cooled 19 CREAR ERAN 20 d PERFORMANCE DATA E M rcs wot Tortue 22 a KML 400MAE Air cooled ee PERCHE UK ed Keen ce dace Ree eU Heb eun a eens 22 b KML 400MWE W
5. 9 Turn on the power supply 5 REMOVAL AND REPLACEMENT OF EXPANSION VALVE IMPORTANT Sometimes moisture in the refrigerant circuit exceeds the Drier capacity and freezes up at the Expansion Valve Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Turn off the power 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 32 A1BAA0219807 4 Remove the insulation and the Expansion Valve Bulb on the suction line 5 Remove the Expansion Valve Cover and disconnect the Expansion Valve using brazing equipment 6 Braze the new Expansion Valve with nitrogen gas flowing at the pressure of 3 4 PSIG 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 250 F 7 Install the new Drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 See the Nameplate for the required refrigerant charge 10 Attach the Bulb to the suction line in position Be sure to secure it with clamps and to insulate it 11 Place the new set of Expansion Valve Covers in position 12 Replace the panels in their correct positions 13 Turn on the power supply 6 REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND LINE VALVE CAUTION Always use a copper tube of the same diameter
6. HOSHIZAKI MODULAR CRESCENT CUBER MODEL KML 400MAE KML 400MWE SERVICE MANUAL FOREWORD IMPORTANT Only qualified service technicians should attempt to service or maintain this icemaker No such service or maintenance should be undertaken until the technician has thoroughly read this Service Manual HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should the reader have any questions or concerns which have not been satisfactorily addressed please call or write to the HOSHIZAKI Care Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn HOSHIZAKI Care Department Phone 1 800 233 1940 Technical Service 770 487 2331 Fax 770 487 3360 NOTE To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem A1BAA0219801 Please review this manual It should be read carefully before the icemaker is serviced or maintenance operations performed Only qualified service technicians should service and maintain the icemaker This manual should be made available to the technician prior to service or maintenance CONTENTS PAGE I SPREGIFICATION S oet POE RERO asa Mola iau le DRAN AD SOROR 1 1 KML 400MAE Air cooled
7. 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 Storage Bin and Scoop e Wash your hands before removing ice Use the plastic scoop provided Accessory The Storage Bin is for ice use only Do not store anything else in the bin Keep the scoop clean Clean it by using a neutral cleaner and rinse thoroughly Clean the bin liner by using a neutral cleaner Rinse thoroughly after cleaning 3 Air Filter Air cooled model only A plastic mesh air filter removes dirt or dust from the air and keeps the Condenser from getting clogged As the filter gets clogged the icemaker s performance will be reduced Checkthe filter atleast twice a month When clogged use warm water and a neutral cleaner to wash the filter 4 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 of the icemaker 47 A1BAA0219807
8. recommended pressure Water Pump will not start or freeze cycle b Water Solenoid Valve Dirty mesh filter or orifice and water level in Water Tank too low Clean time is too short c Water System Water leaks Check connections for water leaks and replace Clogged Clean d Pump Motor Motor winding opened Replace Bearing worn out Replace Wiring to Pump Motor Check for loose connection or open and replace Defective or bound impeller CLEAN e Controller Board 6 Fan Motor will a Fan Motor Defective Motor winding opened See 1 2 e CHECKING CONTROLLER BOARD Replace not start or is Bearing worn out Replace not operating Wiring to Fan Motor Check for loose connection or open and replace Defective Capacitor Replace Fan blade bound Check and replace b Controller Board 7 All componentsja Refrigerant run but no ice Defective Undercharged See 1 2 e CHECKING CONTROLLER BOARD Check for leaks and recharge is produced Air or moisture trapped Replace Drier and recharge b Compressor Defective valve Replace Hot Gas Solenoid Valve Continues to open in freeze cycle Check and replace d Line Valve Continues to close i
9. ADJUSTMENT 2 Defrost Timer Defective Clogged 2 e CHECKING CONTROLLER BOARD Clean Out of position Place in position b Water System Dirty Clean Refrigerant Undercharged Check for leaks and recharge d Expansion Valve Bulb out of position or loose attachment Place in position Defective Replace e Hot Gas Solenoid Valve 3 LOW ICE PRODUCTION POSSIBLE CAUSE PROBLEM Coil winding opened Replace Plunger does not move Replace Wiring to Hot Gas Valve Check for loose connection or open and replace REMEDY 1 Freeze cycle time is long chart 1 3 and check dirty Air Filter or Condenser ambient or water temperature water pressure Water Regulator or refrigerant charge b See chart 2 1 and check Float Switch Water Solenoid Valve or Controller Board 2 Harvest cycle a See chart 2 2 and check Controller Board Thermistor Evaporator ambient time is long and or water temperature water supply line Water Solenoid Valve A1BAA0219807 27 4 ABNORMAL ICE PROBLEM POSSIBLE CAUSE REMEDY 1 Small Cube Ice Cube Guide 1 Out of position Circulated water falls into bin 1 Place in position b See chart 1 5 and check water supply line Water Solenoid Valve water system Pump
10. Auto reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES SUPPLIED N A REQUIRED Ice Storage Bin OPERATION CONDITIONS VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 WATER SUPPLY TEMP 45 90 WATER SUPPLY PRESS 10 113 PSIG We reserve the right to make changes in specifications and design without prior notice 2 A1BAA0219807 GENERAL INFORMATION 1 CONSTRUCTION a KML 400MAE Water Supply Inlet Condenser Spray Tube Fan Motor Condenser Expansion Valve Control Box Water Pump Float Switch Control Switch Bin Control Thermostat Hot Gas Valve Compressor A1BAA0219801 Water Supply Inlet b KML 400MWE 5 5 5 E rs 5 8 FI y 5 AE URN E N A WA Ere SN y ES IN m E a 2 EN 4 Ne a EN L gt O E o t 5 n 9 229 5 iL 42 Water Pump Expansion Valve A1BAA0219801 Hot Gas Valve Thermostat Compressor 2 CONTROLLER BOARD a SOLID STATE CONTROL 1 A HOSHIZAKI exclusive solid state control is employed in KML 400 Series Modular Crescent Cubers 2 A Printed Circuit Board hereafter called Controller Board includes a stable and high quality control system 3 All models are pre tested and factory
11. ICE PRODUCTION PER 24 HR 70 21 429 195 397 180 80 27 421 191 379 172 90 32 419 190 370 168 Ibs day kg day 100 38 412 187 347 157 APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER 70 21 529 2 00 574 2 17 CONSUMPTION PER 24 HR 80 27 563 2 13 634 2 40 90 32 574 2 17 684 2 59 gal day m day 100 38 682 2 58 755 2 86 FREEZING CYCLE TIME min HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE PSIG SUCTION PRESSURE 70 23 80 27 90 32 PSIG 100 38 HEAT OF REJECTION FROM CONDENSER 6100 W 90 F 32 C WT 70 F 21 C HEAT OF REJECTION FROM COMPRESSOR 1250 W 90 F 32 C WT 70 F 21 C WATER FLOW FOR CONDENSER 48 9 gal h AT 100 F 38 C WT 90 F 32 C PRESSURE DROP OF COOLING WATER LINE less than 10 PSIG 0 7 bar Note Pressure data is recorded first 5 minutes in freezing cycle The data without marks should be used for reference We reserve the right to make changes in specifications and design without prior notice 23 A1BAA0219807 IV SERVICE DIAGNOSIS 1 NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY 1 The icemaker will not start a Power Supply 1 OFF position Move to ON position 2 Loose connections 2 Tighten 3 Bad contacts Check for continuity and replace 4 Voltage too high Check and get recommended voltage b Fuse Inside
12. Motor or Controller Board c Drain Valve 2 Cloudy or irregular cube Valve 1 Dirty See chart 2 1 and 3 and check Float Switch Water Solenoid Valve Controller Board Spray Tubes water system refrigerant charge or Expansion b Spray Guide 1 Dirty 1 Clean c Water Quality 5 OTHERS PROBLEM 1 High hardness or contains impurities POSSIBLE CAUSE 1 Install a water filter or softener REMEDY a Bin Control Thermostat 1 Icemaker will not stop when bin is filled with ice 2 Abnormal a Pump Motor 1 Set too cold Adjust warmer 2 Defective Bearings worn out 2 Replace Replace noise b Fan Motor Bearings worn out Replace Fan blade deformed Replace fan blade Fan blade does not move freely Replace c Compressor Bearings worn out or cylinder valve broken Replace Mounting pad out of position Reinstall d Refrigerant Lines 3 Ice in storage a Bin Drain bin often melts Rub or touch lines or other surfaces Plugged 28 Replace A1BAA0219807 V REMOVAL AND REPLACEMENT OF COMPONENTS 1 SERVICE FOR REFRIGERANT LINES a REFRIGERANT RECOVERY The icemaker unit is provided with two Refrigerant Access Valves on the low side and high side lines Recover the refrigerant from the Access Valves and store it in an ap proved container
13. Voltage Cut out If miswiring causes excessive voltage on the Controller Board the High Volt age Cut out shuts down the circuit in 3 seconds and the icemaker automati cally stops When the proper supply voltage is resumed the icemaker auto matically starts running again A1BAA0219801 Connector K1 Pin 1 thru 10 1 9 Magnetic Contactor 2 Hot Gas Valve 3 Line Valve 4 Pump Motor icemaking 5 Pump Motor drain 6 Water Valve 7 10 Power line Bin Control 8 Open Dip Switch Defrost Timer Drain Timer amp Drain Counter Connector K5 Float Switch J ul D 25 4 5 Connector 4 not connected Connector K3 Defrost Control Thermistor Alpine Board A1BAA0219801 c SEQUENCE 1st Cycle 1 Unit energized and Control Switch to ICE 3 Thermistor reads 48 F position Water supply cycle starts Defrost Timer adjustable from 1 to 3 minutes starts counting 2 After 1 minute Defrost cycle starts WATER VALVE WATER VALVE HOT GAS VALVE FREEZE CYCLE ERE 4 IMPORTANT Water Valve opening is limited to 6 minutes PUMP amp FAN 5 After the first 5 minutes in freeze cycle 4 Defrost Timer stops counting Ready to complete freeze cycle when Float Defrost cycle is completed and freeze cycle Switch circuit opens starts IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in fre
14. defrost cycle After Step iii de energize the unit and confirm that the Defrost Timer is in the minimum position Disconnect the resistor from the Controller Board and energize the unit After the 1 minute water supply cycle the defrost cycle starts Re connect a 1 5kQ 3 5kQ resistor to the Connector K3 pins 1 and 2 after the first 2 minutes of the defrost cycle 14 A1BAA0219801 The unit should start the freeze cycle after 1 minute 5 seconds from the resistor connection 3 Check the Controller Board by using test program of the Controller Board i Disconnect the Connector K1 from the Controller Board Set the Dip Switch No 7 and 8 on the Controller Board to the ON position and energize the unit ii The current flows to each Relay from X1 to X4 one after another every time the float is raised and the contacts close See the following chart and check OPEN and CLOSE of Pins of the Connector K1 at each step If the checks are completed turn off the icemaker plug the Connector into the Controller Board as before and set the Dip Switch No 7 and 8 to the OFF posi tion TEST PROGRAM OF CONTROLLER BOARD Float Sw ON OFF Float Sw Float Sw Float Sw Float Sw ON OFF ON OFF ON OFF ON OFF l CLOSE CLOSE Relav X2 OPEN CLOSE Relav X3 OPEN CLOSE Relav X4 OPEN Connector K1 CLOSE Pins 1 and 2 OPEN Connector K1 CLOSE Pins 1 and 3 OPEN Connect
15. depending on the ambient and water temperatures 3 High Temperature Safety 127 7 The temperature of the suction line in the refrigerant circuit is limited by the High Temperature Safety During the defrost cycle the Evaporator temperature rises The Thermistor senses 48 F and starts the Defrost Timer After the Defrost Timer counts down to zero the normal freeze cycle begins If the Evaporator temperature continues to rise the Thermistor will sense the rise in temperature and at 127 x 7 F the Thermistor operates the High Temperature Safety This High Temperature Safety shuts down the circuit and the icemaker auto matically stops To reset the safety turn the power off and back on again This High Temperature Safety protects the unit from excessive temperature 4 Low Water Safety The Controller Board checks the position of the Float Switch at the end of the initial one minute water fill cycle and at the end of each defrost cycle If the Float Switch is in the up position electrical circuit closed the Controller Board changes to the ice making cycle If the Float Switch is in the down position electrical circuit open the Controller Board changes to a one minute water fill cycle before starting the ice making cycle For water cooled model if the water is shut off the unit is protected by the High Pressure Switch 5 High Voltage Cut out The maximum allowable supply voltage of this icemaker is limited by the High
16. determined by the Drain Timer The Drain Timer also determines the time to restrain completion of a defrost cycle i e the minimum defrost time Switch Nos 5 and 6 Used for adjustment of the Drain Counter The Pump Motor drains the Water Tank at the frequency determined by the Drain Counter Switch Nos 7 and 8 Used only for checking the Controller Board Usually set in OFF position A1BAA0219801 1 Defrost Control A thermistor Semiconductor is used for a defrost control sensor The resistance varies depending on the Suction Line temperatures The Thermistor detects the temperature of the Evaporator outlet to start the Defrost Timer No adjustment is required If neces sary check for resistance between Thermistor leads and visually check the Thermistor mounting located on the Suction Line next to the Evaporator outlet Temperature F Resistance kQ 0 14 401 10 10 613 32 6 000 50 3 871 70 2 474 90 1 633 Check a thermistor for resistance by using the following procedures i Disconnect the connector on the board ii Remove the Thermistor See V 11 REMOVAL AND REPLACEMENT OF THER MISTOR iii Immerse the Thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes iv Check for a resistance between Thermistor leads Normal reading is within 3 5 to 7kQ Replace the Thermistor if it exceeds the normal reading 2 Defrost Timer No adjustment is required under normal use a
17. the Thermistor leads through the bushing of the Control Box to the K3 Connector on the Controller Board Note Do not cut the leads of the Thermistor while installing it 12 Replace the Control Box Cover and the panels in their correct positions 13 Turn on the power supply 11 REMOVAL AND REPLACEMENT OF FAN MOTOR Note When replacing a Fan Motor with defective winding it is recommended that a new capacitor be installed 1 Turn off the power supply 2 Remove the panels 3 Remove the closed end connectors from the Fan Motor leads 4 Remove the Fan Motor Bracket and Fan Motor 5 Remove the wiring connectors from the Pump Motor leads 6 Install the new Fan Motor and replace the removed parts in the reverse order of which they were removed 7 Replace the panels in their correct positions 8 Turn on the power supply 39 A1BAA0219807 12 REMOVAL AND REPLACEMENT OF WATER VALVE 1 Turn off the power supply 2 Close the Water Supply Line Shut off Valve 3 Remove the Front Panel 4 Remove the Valve Outlet Tubing by releasing the Clamp 5 Remove the Bracket from the unit 6 Remove the Fitting Nut and Water Valve 7 Disconnect the Terminals from the Water Valve 8 Install the new Water Valve and replace the removed parts in the reverse order of which they were removed 9 Open the Water Supply Line Shut off Valve 10 Turn on the power supply 11 Check for leaks 12 Replace the Front Panel in its cor
18. 0 421 191 406 184 379 172 90 419 190 395 179 370 168 412 187 389 177 347 157 20A Ambient 70 SHAPE OF ICE Crescent Cube ICE PRODUCTION PER CYCLE 6 6 Ibs 3 0 kg 360 pcs APPROXIMATE STORAGE CAPACITY N A ELECTRIC amp WATER CONSUMPTION 90 70 70 50 ELECTRIC W KWH 100 lbs 1131 6 7 1112 6 3 WATER gal 24 HR gal 100 Ibs 103 26 164 38 WATER COOLED CONDENSER 581 147 365 85 gal 24 hr gal 100 Ibs EXTERIOR DIMENSIONS WxDxH 30 x 27318 x 22 762 x 695 x 560 EXTERIOR FINISH Stainless steel Galvanized Steel Rear WEIGHT Net 150 Ibs 60 CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 12 Condenser Inlet 12 DRAIN Outlet 34 FPT Condenser Outlet FPT CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe COOLING WATER CONTROL Pressure Regulator BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic Model RSN6 0075 CAA CONDENSER Water cooled Tube in Tube type EVAPORATOR Vertical type Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic ExpansionValve REFRIGERANT CHARGE R22 15 oz 435 0 DESIGN PRESSURE High 395 PSIG Low 206 PSIG P C BOARD CIRCUIT PROTECTION High Voltage Cut out Relay Internal COMPRESSOR PROTECTION Auto reset Overload Protector Internal REFRIGERANT CIRCUIT PROTECTION
19. CE position Then place the Service Switch in the DRAIN position 6 Replace the Front Panel and turn on the power supply for 2 minutes 7 Turn off the power supply 8 Remove the Front Panel and then remove the Insulation Panel by lifting up the panel slightly and pulling it toward you 9 Pour the cleaning solution into the Water Tank 10 Move the Service Switch to the WASH position 44 A1BAA0219807 11 Replace the Insulation Panel and the Front Panel in their correct positions 12 Turn on the power supply and 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 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 then 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 After 5 minutes turn off the power supply 27 Remove the Front Panel 28 Move the Service Switch to the DRAIN position 29 Replace the Front Panel an
20. Do not discharge the refrigerant into the atmosphere b EVACUATION AND RECHARGE 1 Attach Charging Hoses a Service Manifold and a Vacuum Pump to the system For models with the Line Valve be sure to connect Charging Hoses to both high side and low side lines or the high side line cannot be evacuated because of the Line Valve 2 Turn on the Vacuum Pump 3 Allow the Vacuum Pump to pull down to a 29 9 Hg vacuum Evacuating period depends on pump capacity 4 Close the Low side Valve and High side Valve on the Service Manifold 5 Disconnect the Vacuum Pump and attach a Refrigerant Service Cylinder to the Low side line Remember to loosen the connection and purge the air from the Hose See the Nameplate for the required refrigerant charge Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No 700 88 be used 6 Open the Low side Valve Do not invert the Service Cylinder A liquid charge will damage the Compressor 7 Turn on the icemaker when charging speed gets slow Turn off the icemaker when the Low side Gauge shows approximately O PSIG Do not run the icemaker at negative pressures Close the Low side Valve when the Service Cylinder gets empty 8 Repeat the above steps 4 through 7 if necessary until the required amount of refrigerant has entered the system 9 Close the two Refrigerant Access Valves and disconnect the Hoses and Service Manifold 10 Cap the Access Valv
21. Fused Disconnect if any Blown out Check for short circuit and replace c Control Switch OFF position Move to ICE position 2 Bad contacts Check for continuity and replace d Bin Control Thermostat Tripped with bin filled with ice Remove ice Ambient temperature too cool Increase ambient temperature Set too warm See II 2 d CONTROLS AND ADJUSTMENTS 5 Bin Control Bulb out of position Place in position Bad contacts or leaks bulb Check for continuity and replace e High Pressure Control Bad contacts Check for continuity and replace f Transformer Thermal fuse blown out or coil winding opened Replace 9 Wiring to Controller Board Loose connections or open Check for continuity and replace h Thermistor Leads short circuit or open and High Temperature Safety operates See II 2 d CONTROLS AND ADJUSTMENTS 1 Defrost Control i Hot Gas Solenoid Valve Continues to open in freeze cycle and High Temperature Safety operates Check for power off in freeze cycle and replace j Water Supply Line Water supply off and water supply cycle does not finish Check and get recommended pressure Condenser water pressure too low or off and Pressure Control opens and closes fre quently t
22. OFF The Pump Motor waits for 2 seconds before starting a drain cycle See Il 2 d CONTROLS AND ADJUSTMENTS The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See 1 2 d CONTROLS AND ADJUSTMENTS 21 4 PERFORMANCE DATA a KML 400MAE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs dav kg day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR gal day m day FREEZING CYCLE TIME min HARVEST CYCLE TIME min HEAD PRESSURE PSIG SUCTION PRESSURE PSIG TOTAL HEAT OF REJECTION AMBIENT 70 21 80 27 90 32 100 38 70 21 80 27 90 32 100 38 70 21 80 27 90 32 100 38 70 21 80 27 90 32 100 38 70 21 80 27 90 32 100 38 70 21 80 27 90 32 100 38 70 21 80 27 90 32 100 38 410 186 390 177 375 170 360 164 WATER TEMP TEMP F C 50 10 360 164 840 155 325 148 310 141 246 0 93 188 0 71 140 0 53 134 0 51 Btu h AT 90 F 32 C WT 70 F 21 C Note Pressure data is recorded first 5 minutes in freezing cycle The data without marks should be used for reference We reserve the right to make changes in specifications and design without prior notice FhC 90 32 305 139 290 132 275 125 255 116 214 0 81 172 0 65 116 0 44 KML 400MWE AMBIENT WATER TEMP F C APPROXIMATE TEMP F C 50 10 70 21 90 32
23. adjusted b CONTROLLER BOARD CAUTION Fragile handle very carefully A controller board contains integrated circuits which are susceptible to failure due to static discharge It is especially important to touch the metal part of the unit when handling or replacing the board Do not touch the electronic devices on the board or the back of the board to prevent damage to the board Do not change wiring and connections Especially never misconnect K3 K4 and K5 because the same connector is used for the Thermistor and Float Switch K4 is not connected Do not fix the electronic devices or parts on the board in the field Always replace the whole board assembly when it goes bad Do not short out power supply to test for voltage PART NUMBER TYPE 2U0127 01 MV9KM910 Alpine Note 1 Maximum Water Period 6 minutes A1BAA0219801 Water Solenoid Valve opening in the Defrost Harvest Cycle is limited by maximum period of the defrost timer The Water Valve cannot remain open longer than the maximum period The Water Valve can close in less than the maximum period if the defrost cycle is completed 2 Defrost Timer The defrost cycle starts when the Float Switch opens and completes the freeze cycle But the Defrost Timer does not start counting until the Ther mistor senses 48 F at the Evaporator outlet The period from the end of the freeze cycle up to the point of the Thermistor s sensing varies
24. and length when replacing the hot gas lines otherwise the performance may be reduced 33 A1BAA0219807 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 screw and the Solenoid 5 Disconnect the Hot Gas Valve or Line Valve 6 Install the new valve 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 250 F 7 Install the new Drier 8 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 9 See the Nameplate for the required refrigerant charge 10 Cut the leads of the Solenoid allowing enough lead length to reconnect using closed end connectors 11 Connect the new Solenoid leads 12 Attach the Solenoid to the valve body and secure it with a screw 13 Replace the panels in their correct positions 14 Turn on the power supply 34 A1BAA0219807 7 REMOVAL AND REPLACEMENT OF EVAPORATOR IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repairs or replacement have been made 1 off the power supply 2 Remove the panels and the Top Insulation ov
25. anel 8 Install the new valve and braze the Capillary Tube 9 Install the new Drier 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 11 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 12 Connect the Flare connections 13 Open the Water Supply Line Shut off Valve 14 Check for water leaks 15 Replace the panels in their correct positions 16 Turn on the power supply 36 A1BAA0219807 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 Attach a pressure gauge to the high side line of the system Or prepare a thermometer to check for the condenser drain temperature 2 Rotate the adjustment screw by using a flat blade screwdriver so that the pressure gauge shows the temperature specified in the table 5 minutes after a freeze cycle or icemaking process starts When the pressure exceeds 235 PSIG or the condenser drain temperature exceeds the temperature range rotate the adjustment screw clockwise See Fig 1 3 Check that the pressure or the condenser drain temperature holds a stable setting ADJUSTMENT SCREW CW Lower CCW Higher e B Top View Fig 1 MODEL KML 400MWE WATER TEMP F 50 70 90
26. ater cooled nnns 23 IV SERVICE DIAGNOSIS DROP 24 1 NO ICE PRO DUG TION 24 2 EVAPORATOR IS FROZEN UP 27 S LOW IGE PRODUCTION idit aM kaz za rr Rn 27 d ABNORMAL IE 2 1 2 28 DOO THETIUS A 28 ii A1BAA0219807 V REMOVAL AND REPLACEMENT OF COMPONENTS 29 1 SERVICE FOR REFRIGERANT LINES in vo eot at eorura erbe rettet 29 REFRIGERANT RECOVERY 200 29 b EVACUATION AND RECHARGE 5 tana ra ttu tr rtr kinh tea paida 29 2 BRAZING at aber a it a A a 30 3 REMOVAL AND REPLACEMENT OF COMPRESSOR 30 4 REMOVAL AND REPLACEMENT OF DRIER eene 32 5 REMOVAL AND REPLACEMENT OF EXPANSION VALVE 32 6 REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND M 33 7 REMOVAL AND REPLACEMENT OF EVAPORATOR 35 8 REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE WATER COOLED MODEL 36 9 ADJUSTMENT OF WATER REGULATING VALVE WATER COOLED MODEL a f 37 10 REMOVAL AND REPLACEMENT OF THERMISTOR 38 11 REMOVAL AND REPLACEMENT OF FAN MOTOR
27. d Steel Rear WEIGHT Net 150 16 68 kg CONNECTIONS ELECTRIC Permanent Connection WATER SUPPLY Inlet 2 Outlet CUBE CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe COOLING WATER CONTROL N A BIN CONTROL SYSTEM Thermostat COMPRESSOR Hermetic Model RSN6 0075 CAA CONDENSER Air cooled Fin and Tube type EVAPORATOR Vertical type Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic ExpansionValve REFRIGERANT CHARGE R22 11b 5 610g DESIGN PRESSURE High 427 PSIG Low 206 PSIG P C BOARD CIRCUIT PROTECTION High Voltage Cut out Internal COMPRESSOR PROTECTION Auto reset Overload Protector Internal REFRIGERANT CIRCUIT PROTECTION Auto reset High Pressure Control Switch LOW WATER PROTECTION Float Switch ACCESSORIES SUPPLIED N A REQUIRED Ice Storage Bin OPERATION CONDITIONS VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESS 10 113 PSIG We reserve the right to make changes in specifications and design without prior notice A1BAA0219801 2 KML 400MWE AC SUPPLY VOLTAGE 115 60 1 AMPERAGE 11 5 A 5 MIN Freeze 104 F WT 80 MINIMUM CIRCUIT AMPACITY 20A MAXIMUM FUSE SIZE APPROX ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks 50 70 90 429 195 419 190 397 180 8
28. d to the pump and the Bypass solenoid valve This cleans both the inside and outside of the evaporator plate assembly 3 Circulate When the Service switch is active and placed in the center position power is supplied to the pump only This operation can be used to circulate cleaner for extended periods of time over the outside surface of the Evaporator 16 A1BAA0219802 TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT a KML 400MAE Condenser Spray Tube Water High Pressure valve Switch Evaporator Thermistor Strainer Hot Gas Valve Discharge Line Drain Compressor f Access Valve Expansion Valve Refrigerant Circuit mmEm Water Circuit A1BAA0219801 b KML 400MWE Water Regulating Condenser Valve I Water Valve Spray Tube Water Supply High Pressure Switch Evaporator Drier Thermistor Insulation Tube Strainer Float Switch Compressor Drain L3 Access Valve NExpansion Valve Refrigerant Circuit mm Water Circuit 18 A1BAA0219801 KML 400MAE Pressure Switch 2 WIRING DIAGRAMS Cut out 384 21 3 PSIG Cut in 284 5 21 3 PSIG KML 400MAE KML 400MWE KML 400MWE Pressure Switch Cut out 355 6 21 3 PSIG Cutin 256 21 3 PSIG 1300W 041002 AINO 1050000 18004 031002 X3LYM AINO L 08 liom
29. d turn on the power supply for 2 minutes 30 Turn off the power supply 31 Remove the Front Panel 31 Repeat the above 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 45 A1BAA0219807 3 SANITIZING PROCEDURE Following Cleaning Procedure 1 Dilute IMS II Sanitizer or a 5 25 Sodium Hypochlorite solution with water Add 1 0 fl oz to 2 gal of water Note IMS II Sanitizer Part 0004 is available through your Hoshizaki Dealer 2 Remove the Insulation Panel 3 Pour the sanitizing solution into the Water Tank 4 Move the Service Switch to the WASH position 5 Replace the Insulation Panel and the Front Panel in their correct position 6 Turn on the power supply and 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 and turn on the power supply for 2 minutes 11 Turn off the power supply 12 Remove the Front Panel 13 Repeat the above steps 18 through 31 in 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 with water 17 Turn on the power supply and start the automatic icemaking process 46 A1BAA0219807 4
30. e Water Line Drain Valve 7 Move the Control Switch to the ICE position 8 Replace Front Panel and turn on the power supply 9 Blow the potable water line out using compressed air or carbon dioxide 3 Drain the Potable Water Tank 1 Turn off the power supply 2 Remove the Front Panel 3 Move the Control Switch to SERVICE and move the Service Switch to the DRAIN position 4 Replace the Front Panel and turn on the power supply for 2 minutes 5 Turn off the power supply 43 A1BAA0219807 2 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 Always wear liquid proof gloves for safe handling of the cleaning and sanitizing solution This will prevent irritation in case the solution contacts with skin 1 Dilute approximately 10 5 fl oz of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 2 gal of water 2 Remove all ice from the Evaporator and the Storage Bin Note To remove cubes on the Evaporator turn off the power supply and turn it on after 3 minutes The defrost cycle starts and the cubes will be removed from the Evaporator 3 Turn off the power supply 4 Remove the Front Panel 5 Place the Control Switch in the SERVI
31. er the Evaporator 3 Recover the refrigerant and store it in an approved container 4 Remove the Spray Tube and the Insulated Rubber Tube at the U shaped notch where the refrigeration tubings go through the chassis 5 Remove the Insulation Tube and disconnectthe Evaporator Inlet Tubing atthe Tee next to the Expansion Valve 6 Lift up the Evaporator and disconnect the Evaporator Outlet Tubing 7 Install the new Evaporator 8 Install the new Drier 9 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 10 Evacuate the system and charge it with refrigerant See the Nameplate for the required refrigerant charge 11 Replace the removed parts in the reverse order of which they were removed 12 Replace the Top Insulation and the panels in their correct positions 13 Turn on the power supply 35 A1BAA0219807 8 REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE WATER COOLED MODEL ONLY 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 Close the Water Supply Line Shut off Valve 3 Remove the panels 4 Recover the refrigerant and store it in an approved container 5 Disconnect the Capillary Tube at the Condenser outlet using brazing equipment 6 Disconnect the Flare connections of the valve 7 Remove the screws and the valve from the Rear P
32. es to prevent a possible leak 29 A1BAA0219807 2 BRAZING WARNING 1 Refrigerant R22 itself is not flammable explosive or poisonous How ever when exposed to an open flame R22 creates Phosgene gas hazardous in large amounts 2 Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere 3 Do not use silver alloy or copper alloy containing Arsenic Note All brazing connections in the Evaporator Case are clear paint coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove paint 3 REMOVAL AND REPLACEMENT OF COMPRESSOR IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made Note When replacing a Compressor with a defective winding be sure to install the Start Capacitor Run Capacitor and Start Relay supplied with the replacement Compressor 1 Turn off the power supply 2 Remove the panels 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 Discharge and Suction Pipes using brazing equipment 6 Remove the Hold down Bolts Washers and Rubber Grommets 30 7 Slide and remove the Compressor Unpack the new Compressor package Install the new Compr
33. essor 8 Attach the Rubber Grommets of the prior Compressor 9 Sandpaper the Suction Discharge and Process Pipes 10 Place the Compressor in position and secure it using the Bolts and Washers 11 Remove plugs from the Suction Discharge and Process Pipes 12 Braze the Process Suction and Discharge lines Do not change this order while purging with nitrogen gas flowing at the pressure 3 4 PSIG 13 Install the new Drier 14 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 15 See the Nameplate for the required refrigerant charge 16 Connect the Terminals and replace the Terminal Cover in its correct position 17 Replace the panels in their correct positions 18 Turn on the power supply 31 A1BAA0219807 4 REMOVAL AND REPLACEMENT OF DRIER IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Turn off the power supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the Drier 5 Install the new Drier with the arrow on the Drier in the direction of the refrigerant flow Use nitrogen gas at the pressure of 3 4 PSIG when brazing the tubings 6 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 7 See the Nameplate for the required refrigerant charge 8 Replace the panels in their correct positions
34. eze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting A1BAA0219801 2nd Cycle and after with pump drain IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open 1 Float Switch opens and signals to complete freeze cycle 10 20 second Drain Timer starts counting 2 Drain Timer stops counting Pump drain is completed DRAIN VALVE PUMP amp FAN 5 After the first 5 minutes in freeze cycle Ready to complete freeze cycle when Float Switch circuit opens IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in freeze cycle A1BAA0219801 3 Thermistor reads 48 F Defrost Timer adjustable from 1 to 3 minutes starts counting IMPORTANT Water Valve opening is limited to 6 minutes 4 Defrost Timer stops counting Defrost cycle is completed and freeze cycle starts IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 2nd Cycle and after with no pump drain IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open 1 Float Switch opens and signals
35. is not used for two or three days itis sufficient to only move the Control Switch to the OFF position unless the 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 2 Remove the Front Panel 3 Move the Control Switch on the Control Box to the OFF position 4 Wait 3 minutes 5 Move the Control Switch to the ICE position 6 Replace the Front Panel and turn on the power supply 7 Allow 5 minutes for the icemaker to fill with water and the Water Pump to start operating 8 Close the Water cooled Condenser Water Supply Line Shut off Valve See Fig 4 9 Open the Drain Valve for the water cooled condenser water supply line 10 Allow the line to drain by gravity 11 Quickly attach compressed air or carbon dioxide supply to the Condenser Water Line Drain Valve 12 Blow the water cooled Condenser out using compressed air or carbon dioxide until water stops coming out 42 A1BAA0219807 2 Remove the water from the potable 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 Wait 3 minutes 4 Closethe Potable Water Supply Line Shut off Valve and open the Potable Water Supply Line Drain Valve See Fig 4 5 Allow the line to drain by gravity 6 Attach compressed air or carbon dioxide supply to the Potabl
36. n freeze cycle Check and replace e Water Supply Line Water cooled model only Condenser water pressure too low or off and Pressure Control opens and closes frequently 26 Check and get recommended pressure A1BAA0219807 2 EVAPORATOR IS FROZEN PROBLEM POSSIBLE CAUSE REMEDY 1 Freeze cycle time is too long 2 All ice formed on Evaporator does not fall into bin in harvest cycle 3 Others a Float Switch Leads short circuit or defective switch Check and replace Float does not move freely Clean or replace b Water Solenoid Valve Diaphragm does not close Check for water leaks with icemaker off c Controller Board a Evaporator Defective Scaled up See 1 2 CHECKING CONTROLLER BOARD Clean b Water Supply Line Water pressure too low Check and get recommended pressure c Water Solenoid Valve Dirty mesh filter or orifice Clean 2 Diaphragm does not close 2 Check for water leaks with icemaker off d Ambient and or water temperature Too cool Increase temperature e Thermistor Out of position or loose attachment See V 11 REMOVAL AND REPLACEMENT OF THERMISTOR f Controller Board a Spray Tube Defrost Timer is set too short Adjust longer referring to Il 2 d CONTROLS AND
37. o finally operate High Temperature Safety Check and get recommended pressure k Water Solenoid Mesh filter or orifice gets clogged and water supply cycle does not finish Clean Coil winding opened Replace Wiring to Water Valve 24 Check for loose connection or open and replace A1BAA0219807 POSSIBLE CAUSE REMEDY Controller Board 2 Water continues to be supplied and the ice a Float switch Defective Connector disconnected See 11 2 CHECKING CONTROLLER BOARD Place in position 2 Leads opened or defective switch 2 Check and replace Float does not move freely 3 Clean or replace maker will not b Controller Board start 3 Compressor a Control Switch Defective SERVICE position Replace Move to ICE position 2 Bad contacts 2 Check and replace b High Pressure Controller Dirty Air Filter or Condenser Clean Ambient or condenser water temp too warm Reduce ambient temp Refrigerant overcharged Recharge Condenser water pressure too low or off Water cooled model only Check and get recommended pressure Fan not operating Except water cooled model See chart 1 6 Refrigerant line or components plugged Clean and replace Drier c Wate
38. or 1 CLOSE Pins 1 and 4 OPEN Connector Ki CLOSE Pins 1 and 5 OPEN Connector CLOSE Pins 6 and 7 OPEN Connector 1 CLOSE Pins 9 and 10 A1BAA0219801 3 SWITCHES Two control switches are used to control operation the KML Series Modular Crescent Cubers These switches are referred to as the Control Switch and the Service Switch CONTROL SWITCH The Control Switch is located on the lower left section of the control box when facing the front of the machine This switch is used to place the machine into one of three modes Power Off Center position Ice Making Right position and Service Left position b SERVICE SWITCH When the Control Switch is pushed to the left the machine is placed in Service mode In this position the Control Switch supplies power to the Service Switch The Service Switch can be used to perform three funtions Drain the tank left position Circulate water center position Wash the ice making compartment right position When the Service Switch is activated power is supplied to the pump in all three positions 1 Drain The KML series utilizes a pump out drain system When the Service Switch is active and placed in the left position power is supplied to the pump and the Drain solenoid valve 2 Wash The KML series utilizes a solenoid operated cleaning valve When the Service Switch is active and placed in the right position power is supplie
39. r Regulator Set too high Adjust lower d Overload Protector Bad contacts Check for continuity and replace Voltage too low Increase voltage Refrigerant overcharged or undercharged Recharge Line Valve continues to close in freeze cycle and Overload Protector operates Check Line Valve s operation in freeze cycle and replace e Starter Bad contacts Check and replace 2 Coil winding opened 2 Replace f Start Capacitor or Run Capacitor Defective Replace g Magnetic Contactor Bad contacts Check for continuity and replace 2 Coil winding opened 2 Replace h Compressor Wiring to Compressor Check for loose connection or open and replace Defective Replace Protector tripped Reduce temperature i Controller board A1BAA0219807 Defective 25 1 2 e CHECKING CONTROLLER BOARD PROBLEM POSSIBLE CAUSE REMEDY 4 Water continues to Valve a Water Solenoid 1 Diaphragm does not close Check for water leaks with icemaker off be supplied in b Controller Board 1 freeze cycle b No water comes from Spray Tubes a Water Supply Line Defective Water pressure too low and water level in Water Tank too low See 2 CHECKING CONTROLLER BOARD Check and get
40. rect position 13 REMOVAL AND REPLACEMENT OF PUMP MOTOR 1 Turn off the power supply 2 Remove the Front Panel 3 Remove the three screws and the Float Switch Assembly 4 Remove the wiring connectors from the Pump Motor leads 5 Remove the four screws and the Pump Motor 5 Install the new Pump and replace the removed parts in the reverse order of which they were removed 6 Turn on the power supply and check for leaks 7 Replace the Front Panel in its correct position 40 A1BAA0219807 14 REMOVAL AND REPLACEMENT OF SPRAY TUBE A1BAA0219807 1 Turn off the power supply 2 Remove the Front Panel and the Insulation Panel 3 Release the Clamps and disconnect the Rubber Hoses 4 Remove the Spray Tubes by squeezing the side tabs 5 Install the new Spray Tubes and replace the removed parts in the reverse order of which they were removed 6 Replace the panels in their correct positions 7 Turn on the power supply 41 VI CLEANING AND MAINTENANCE INSTRUCTIONS 1 PREPARING THE ICEMAKER FOR LONG STORAGE CAUTION 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 The Storage Bin should be cleaned and dried Drain the icemaker to prevent damage to the water supply line at sub freezing temperatures using air or carbon dioxide Shut off the icemaker until the proper ambient temperature is resumed e When the icemaker
41. s the Defrost Timer is adjusted to the suitable position However if necessary when all the ice formed on the Evaporator does not fall into the bin in the harvest cycle adjust the Defrost Timer to longer position by setting the Dip Switch No 1 amp 2 on the Controller Board SETTING TIME Dip Switch Dip Switch No 1 No 2 OFF OFF 60 seconds ON OFF 90 seconds OFF ON 120 seconds ON ON 180 seconds 12 A1BAA0219801 3 Drain Timer The Drain Timer is factory adjusted and no adjustment is required SETTING TIME Dip Switch Dip Switch No 3 No 4 T1 T2 OFF OFF 10 seconds 150 seconds ON OFF 10 seconds 180 seconds OFF ON 10 seconds 120 seconds ON ON 20 seconds 180 seconds T1 Time to drain the Water Tank T2 Time to restrain defrost completion 4 Drain Counter CAUTION Do not adjust the Drain Counter or the Evaporator may freeze up Except for some B type models the Drain Counter 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 Drain Counter can be adjusted as shown in the table below SETTING FREQUENCY Dip Switch Dip Switch No 5 No 6 OFF OFF every cycle ON OFF every 2 cycles OFF ON every 5 cycles ON ON every 10 cycles A1BAA0219801 5 Bin Control CAUTION When the ambient temperature is below 45 F the Bin Control Thermostat operates to stop the icemaker even if the Ice S
42. to complete 2 Thermistor reads 48 F freeze cycle Defrost Timer adjustable from 1 to 3 minutes starts counting WATER VALVE DEFROST CYCLE 2 IMPORTANT Water Valve opening is limited to 6 minutes PUMP amp FAN 3 Defrost Timer stops counting Defrost cycle is completed and freeze cycle starts 4 After the first 5 minutes in freeze cycle Ready to complete freeze cycle when Float Switch circuit opens IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in freeze cycle 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 10 A1BAA0219801 d CONTROLS AND ADJUSTMENTS Alpine Alpine Board The Dip Switch is factory adjusted to the following positions DIP SWITCH NO 1 2 3 4 5 16 7 8 EEO OFF OFF OFF OFF ON ON OFF OFF KML 400MWE Switch Nos 1 and 2 Used for adjustment of the Defrost Timer The Defrost Timer starts counting when the Thermistor reads a certain temperature at the Evaporator outlet Switch Nos 3 and 4 Used for adjustment of the Drain Timer When a freeze cycle is completed the Pump Motor stops and the icemaker resumes operation in 2 seconds Then the Pump Motor drains the Water Tank for the time
43. torage Bin is empty When the Thermostat is set in the prohibited range the icemaker operates continuously even if the Ice Storage Bin is filled with ice Setting in the prohibited range might cause severe damage to the icemaker resulting in failure No adjustment is required under normal use as the Bin Control is factory adjusted Adjust it if necessary so that the icemaker stops automatically in approximately 6 to 10 seconds after ice contacts the Bin Control Thermostat Bulb e CHECKING CONTROLLER BOARD 1 Visually check the sequence with the icemaker operating 2 Visually check the Controller Board by using the following procedures i Adjust the Defrost Timer to minimum position ii iii iv Disconnect the Thermistor from the Controller Board Connect a 1 5kQ 3 5kQ resistor to the Connector K3 pins 1 and 2 and energize the unit After the 1 minute x 5 second water supply cycle and the 2 minute 10 second defrost cycle the unit should start the freeze cycle After the above step i disconnect the Float Switch leads from the Controller Board within the first 5 minutes of the freeze cycle The unit should go into the defrost cycle after the first 5 minutes 20 seconds of the freeze cycle Reconnect the Float Switch Connector to the Controller Board After the first 5 minutes of the freeze cycle disconnect the Float Switch leads from the Controller Board At this point the unit should start the
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