KM 280M H Service Manual
Contents
1. 5 2a KM 280MWH Water cooled Serial 00001 M10134C 6 2b KM 280MWH Water cooled Serial M20315D 7 Il GENERAL INFORMATION e 8 T CONSTRUG TION iret ie o cdit dee ta Ee eqq oae ciem es 8 a 280 8 b KM 280MWH 9 2 BOARD eii 10 a 2 10 b CONTROLLER BOARD 2 10 C SEQUENCE 14 d CONTROLS AND 17 e CHECKING CONTROLLER BOARD 21 3 MECHANICAL BIN CONTROL 22 PROXIMITY SWITCH eb 22 b EXPLANATION OF 22 adc te oe euenire 23 TECHNICAL 24 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 24 280 PDC 24 1 28 S 25 2 WIRING DIAGRAMS deti oe eek Sheil ed tend ad add eda ect 26 a KM 280MAH and 2802. HOSHIZAKI MODULAR CRESCENT CUBER MODEL KM 280MAH KM 280MWH SERVICE MANUAL Only qualified service technicians should attempt to service or maintain this icemaker No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should the reader have any questions or concerns which have not been satisfactorily addressed please call or write to the HOSHIZAKI Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn HOSHIZAKI Technical Support Department Phone 1 800 233 1940 Technical 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 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 SPEGIFICATIONS ot 5 1 KM 280MAH Air cooled
3. Bad contacts Check for continuity and replace Voltage too high Check and get recommended voltage b Fuse Inside Fused Disconnect if any Blown out Check for short circuit and replace Control Switch OFF position Move to ICE position Bad contacts Check for continuity and replace d Bin Control Thermostat For mechanical bin control see Il 3 c 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 4 Place in position Bad contacts or leaks bulb 5 Check for continuity and replace 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 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
4. To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners Always wear liquid proof gloves for safe handling of the cleaning and sanitizing solution This will prevent irritation in case the solution comes into contact with skin IMPORTANT The Cleaning Valve is used to allow solution flow to the inside of the Evaporator during the cleaning and sanitizing operation It should be closed for all icemaking operation The Compressor will not operate unless this valve is completely closed To open the Cleaning Valve the Valve Handle should be parallel to the valve body To close the valve the Valve Handle should be at a right angle to the valve body CLOSE POSITION OPEN POSITION 54 CLEANING PROCEDURE 1 Dilute 16 fl oz of the recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 3 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 and then remove the Insulation Panel by first removing the thumbscrew lifting the panel slightly and pulling it toward you 5 Remove the Base Cover 6 Drain the Water Tank by removing one end of the Pump Tubing See Fig 4 7 Replace the removed parts in
5. 26 TTMING CHAR a E 28 oc Usar DRE DD Gd 30 KM 280MAH s aee e oq o qr a ii Sed ons 30 b KM 280MWH Serial 1 00001 10134 31 c KM 280MWH Serial 203150 32 IV SERVICE DIAGNOSIS 33 TINO ICE PRODUCTION rie ter 33 2 EVAPORATOR IS FROZEN UP teta 36 3 COWICE PRODUCTION aci aceite i 37 45 ABNORMAPMNIGE a EREE AA 37 5 OTHERS E M 37 V REMOVAL AND REPLACEMENT OF 38 1 SERVICE FOR REFRIGERANT LINES entes 38 a REFRIGERANT RECOVERY csssscescscescccscsececesceccssescesssessusesseceeseterseessseses 38 b EVACUATION AND RECHARGE 404 38 aceite 39 3 REMOVAL AND REPLACEMENT OF 5 40 4 REMOVAL AND REPLACEMENT OF DRIER en 42 5 REMOVAL AND REPLACEMENT OF EXPANSION VALVE 42 6 REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND EINE VALVE Lc EE 43 7 REMOVAL AND REPLACEMENT OF EVAPORATO
6. Check the adjustment chart published in the Tech Specs for proper settings If the old board does not have these two dip switches only 8 instead of 10 leave setting as OFF OFF SETTING TIME Dip Switch Dip Switch No 9 No 10 OFF OFF 60 min ON OFF 70 min OFF ON 50 min ON ON 60 min 6 Bin Control MODELS WITH THERMOSTAT CAUTION When the ambient temperature is below 45 F the Bin Control Thermostat operates to stop the icemaker even if the Ice Storage Bin is empty When the Thermostat is set in the prohibited range the icemaker operates con tinuously even if the Ice Storage Bin is filled with ice Setting in the prohib ited 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 Ad just it if necessary so that the icemaker stops automatically within 10 seconds after ice contacts the Bin Control Thermostat Bulb 20 MODELS WITH MECHANICAL BIN CONTROL CAUTION Dip Switch No 7 must be set to the ON position If No 7 is setto the OFF position the machine will run continuously causing a freeze up condition No adjustment is required The Bin Control is factory adjusted e CHECKING THE CONTROLLER BOARD 1 Visually check the sequence with the icemaker operating 2 Visually check the Controller Board by using the following procedures i ii iv Adjust the Defrost Timer to minimum p
7. 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 E 4 Disconnect the Thermistor leads from RHA the Connector on the Controller Board Y 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 48 Note For models with the Liquid Bypass the Thermistor should be located upstream from the Liquid Bypass outlet and its end should be 4 3 4 or more away from the outlet See Fig 3 Min 4 3 4 Liquid Bypass s SS dn Fig 3 10 Secure the insulation using the Plastic Cable Ties 11 Connect the Thermistor leads through th
8. 4 Remove the screw and the Solenoid 5 Disconnect the Hot Gas Valve or Line Valve using brazing equipment 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 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the Nameplate for the required refrigerant charge For remote air cooled models see the Charge Label in the machine compartment 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 44 7 REMOVAL AND REPLACEMENT 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 Turn off the power supply 2 Remove the panels and the Top Insulation over the Evaporator 3 Recover the refrigerant and store it in an approved container 4 Remove the Spray Tubes and the Insulations at the U shaped notch where the refrigeration tubings go through the molded chassis 5 Remov
9. CLEANING AND MAINTENANCE INSTRUCTIONS IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment 1 PREPARING THE ICEMAKER FOR LONG STORAGE WARNING When shutting off the icemaker for an extended time drain out all water from the water tank and remove the ice from the Storage Bin The Storage Bin should be cleaned and dried Drain the icemaker to prevent damage to the water supply line at sub freezing temperatures using air or carbon dioxide Shut off the icemaker until the proper ambient temperature is resumed When the icemaker is not used for two or three days it is sufficient to only move the Control Switch to the OFF position unless the icemaker will be at sub freezing tem peratures 1 On water cooled model only first remove the water from the water cooled condenser 1 Remove the Front Panel 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 Allow 5 minutes for the icemaker to fill with water and the Water Pump to start operating 6 Close the Water cooled Condenser Water Supply Line Shut off Valve 7 Open the Drain Valve for the water cooled condenser water supply line 8 Allow the line to drain by gravity 52 9 Attach compressed air or carbon dioxide supply to the Condenser Water Line Drain Valve 10 Quickly bl
10. IMPORTANT The vacuum level and Vacuum Pump may be the same as those for current refrigerants However the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils 2 Turn on the Vacuum Pump Never allow the oil in the Vacuum Pump to flow backward 3 Allow the Vacuum Pump to pull down to a 29 9 Hg vacuum Evacuating period de pends on pump capacity 38 4 Close Low side Valve and High side Valve on the Service Manifold 5 Disconnect the Vacuum Pump and attach a Refrigerant Service Cylinder to the High side line Remember to loosen the connection and purge the air from the Hose See the Nameplate for the required refrigerant charge Hoshizaki recommends only virgin refriger ant or reclaimed refrigerant which meets ARI Standard No 700 88 be used 6 A liquid charge is recommended for charging an R 404A system Invert the service cylinder Open the High side Service Manifold Valve 7 Allow the system to charge with liquid until the pressures balance 8 If necessary add any remaining charge to the system through the Low side Use a throttling valve or liquid dispensing device to add the remaining liquid charge through the Low side access port with the unit running 9 Close the two Refrigerant Access Valves and disconnect the Hoses and Service Mani fold 10 Cap the Access Valves to prevent a possible leak 2 BRAZING DANGER Refrigerant R 4044 i
11. S IMPORTANT 2 Water Valve opening is limited to 6 a minutes amp LINE VALVE if Q 5 After the first 5 minutes in freeze cycle Ready to complete freeze cycle when Float 4 Defrost Timer stops counting Defrost cycle is completed and freeze cycle starts Switch circuit opens IMPORTANT Board never accepts freeze completion signal within the first 5 minutes in freeze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 15 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 to complete 2 Thermistor reads 48 F freeze cycle Defrost Timer starts counting WATER VALVE 1 I DEFROST CYCLE 2 Water Valve opening is limited to 6 minutes PUMP amp FAN amp LINE VALVE 4 After the first 5 minutes in freeze cycle 3 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 freeze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is
12. position for normal operation 12 The application switch located between relay 8 X4 must be to match the original board application Place this switch in the ALP position if there is no white wire supplied to the K1 connector If there is a white wire place the switch in the C position If this switch is placed in the wrong position either the compressor contactor will remain ener gized with the control switch OFF or the unit will not start The dip switches should be adjusted per the adjustment chart published in the Tech Specs book Number 8 must remain in the OFF position Output Test Switch Used to test Relays on Board Dip Switch Alarm Reset Switch 0008810 OUTPUT TEST Backup Freeze Timer LED Defrost Control R39 Thermistor 5 30 00 60 10 S Connector K4 red Connected for mechanical bin control models only not connected when used with thermostat bin control Backup Defrost Timer LED Alarm Buzzer Microprocessor Will indicate Board revision level on attached label last 2 digits Power LED Lights up when power is supplied to the Board Connector K5 black Float Switch Part Number Connector K1 Pins 1 through 10 31 9 Magnetic Contactor 2 Hot Gas Valve 3 Line Valve 4 Pump Motor icemaking 5 Pump Motor drain 6 Water Valve 7 10 Pow
13. 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 46 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 270 PSIG or the condenser drain temperature exceeds the temperature range rotate the adjustment screw counterclockwise See Fig 1 3 Check that the pressure or the condenser drain temperature holds a stable setting ADJUSTMENT SCREW ADJUSTMENT SCREW CW Higher CCW Lower 9 Top View Fig 1 47 10 REMOVAL AND REPLACEMENT THERMISTOR CAUTION Fragile handle very carefully Always use a recommended sealant High Thermal Conductive Type
14. F C 90 32 70 21 249 80 27 237 90 32 224 Ibs day _kg day 100 38 215 APPROXIMATE ELECTRIC 70 21 807 CONSUMPTION 80 27 810 90 32 812 watts 100 38 815 APPROXIMATE WATER 70 21 441 CONSUMPTION PER 24 HR 80 27 516 90 32 524 gal day m day 100 38 652 FREEZING CYCLE TIME 70 21 22 80 27 23 90 32 24 min 100 38 25 HARVEST CYCLE TIME 70 24 3 0 80 27 2 7 90 32 2 3 min 100 38 2 2 HEAD PRESSURE 70 21 283 80 27 284 90 32 284 PSIG kg cm G 100 38 287 SUCTION PRESSURE 70 21 51 80 27 53 90 32 54 PSIG 100 38 57 TOTAL HEAT OF REJECTION FROM CONDENSER 4130 BTU h AT 90 F 32 WT 70 F 219C TOTAL HEAT OF REJECTION FROM COMPRESSOR 905 BTU h AT 90 F 32 WT 70 F 21 C WATER FLOW FOR CONDENSER PRESSURE DROP OF COOLING WATER LINE less than 10 PSIG Note Pressure data is recorded at 5 minutes into freeze cycle The data not with should be used for reference only We reserve the right to make changes in specifications and design without prior notice 32 25 gal h AT 100 F 38 WT 90 F 32 C 4 eo l N N o o N o IS lo O IN lO IV SERVICE DIAGNOSIS 1 NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY 1 The icemaker will not start a Power Supply OFF position Move to position Loose connections Tighten
15. power supply 11 Check for leaks 12 Replace the Front Panel in its correct position 13 REMOVAL AND REPLACEMENT OF PUMP MOTOR 1 Turn off the power supply 2 Remove the Front Panel 50 3 Remove the Base Cover 4 Drain the Water Tank by removing one end of the Pump Tubing 5 Replace the removed parts in their correct positions 6 Disconnect the Pump Suction and Discharge Hoses 7 Remove the screws and the Pump Motor Bracket 8 Remove the closed end connectors from the Pump Motor leads 9 Remove the two screws and the Pump Motor Bracket 10 Remove the Pump Housing and check the Impeller 11 If the Impeller is defective install a new Impeller 12 Install the new motor or new parts and replace the removed parts in the reverse order of which they were removed 13 Turn on the power supply and check for leaks 14 Replace the Base Cover in its correct position 15 Replace the Front Panel in its correct position 14 REMOVAL AND REPLACEMENT OF SPRAY TUBES 1 Turn off the power supply 2 Remove the Front Panel and the Insulation Panel 3 Remove the Rubber Hoses from the Spray Tubes Water Supply Pipe 4 Release the Clamps and disconnect the Rubber Hoses 5 Remove the Spray Tubes by squeezing the side tabs 6 Install the new Spray Tubes and replace the removed parts in the reverse order of which they were removed 7 Replace the panels in their correct positions 8 Turn on the power supply 51 VI
16. 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 frequently to finally operate High Temperature Safety 2 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 Check for loose connection or open and replace PROBLEM POSSIBLE CAUSE REMEDY I Controller Board 1 Defective See Il 2 e CHECKING CONTROLLER BOARD m Interlock Switch Cleaning Valve 2 Water continues to be supplied and the ice a Float switch 1 OFF position Move to ON position Bad contacts Connector disconnected 2 Check for continuity and replace Place in position Leads opened or defective switch Check and replace Float does not move freely Clean or replace maker will not b Controller Board start 3 Compressor a Wash Switch Defective WASH position Replace Move to ICE position Bad contacts Check and replace b High Pressure Controller Dirty Air Filter or Condenser Clean Ambient or condenser water temp too warm Reduce ambient temp Refrigerant overcharg
17. the ice formed on the Evaporator does not fall into the bin in the harvest cycle adjust the Defrost Timer to longer setting by adjusting 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 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 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 19 SETTING FREQUENCY Dip Switch Dip Switch No 5 No 6 OFF OFF every cycle ON OFF every 2 cycles OFF ON every 5cycles ON ON every 10 cycles 5 Freeze Timer CAUTION Adjust to proper specification or the unit may not operate correctly Two new dip switches numbered 9 and 10 have been added to the improved E board to better prevent possible freeze ups These settings come factory set to the default setting of 60 min OFF OFF
18. EMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 2 KM 280MWH Water cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 lbs WATER COOLED CONDENSER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS Serial 100001 M10134C 115 6071 10 5 Min Freeze AT 104 F WT 80 F Ambient WATER TEMP F Temp F 50 70 90 Crescent Cube 4 7 lbs 2 16 kg 240 pcs N A 90 70 F 70 50 F 840 9 5 830 7 9 81 38 3 97 38 6 396 187 192 76 22 x 27 3 8 x 30 5 16 560 x 695 x 770 mm Stainless Steel Galvanized Steel Rear Net 151 Ibs 69 kg Shipping 175 Ibs 80 kg Permanent C
19. Fan blade deformed Replace fan blade Fan blade does not move Replace freely c Compressor Bearings worn out or Replace cylinder valve broken Mounting pad out of Reinstall position d Refrigerant Lines Rub or touch lines or other Replace surfaces 3 Ice in storage a Bin Drain Plugged bin often melts 37 V REMOVAL AND REPLACEMENT OF COMPONENTS IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after the equipment is serviced IMPORTANT 1 The Polyol Ester POE oils used in R 404A units can absorb moisture quickly Therefore itis importantto prevent moisture from entering the system when replacing or servicing parts 2 Always install a new filter drier every time the sealed refrigeration system is opened 3 Do not leave the system open for longer than 5 minutes when replacing or servicing parts 1 SERVICE FOR REFRIGERANT LINES a REFRIGERANT RECOVERY The icemaker unit is provided with two Refrigerant Access Valves one on the low side and one on the high side line Using proper refrigerant practices recover the refrigerant from the Access Valves and store it in an approved container Do not discharge the refrigerant into the atmosphere b EVACUATION AND RECHARGE R 404A 1 Attach Charging Hoses a Service Manifold and a Vacuum Pump to the system Be sure to connect charging hoses to both High and Low side Access Valves
20. High Pressure Switch 5 High Voltage Cutout The maximum allowable supply voltage of this icemaker is limited by the High Voltage Cutout If miswiring especially on single phase 3 wire models causes excessive voltage on the Controller Board the High Voltage Cutout shuts down the circuit in 3 seconds and the icemaker automatically stops When the proper supply voltage is resumed the icemaker automatically starts running again The Control Board will signal this problem using 7 Beeps every 3 seconds 6 LED Lights and Audible Alarm Safeties The red LED indicates proper control voltage and will remain on unless a control voltage problem occurs At startup a 5 second delay occurs while the board conducts an internal timer check A short beep occurs when the power switch is turned ON or OFF 11 The green LED s 1 4 represent the corresponding relays energize and sequence 5 seconds from initial start up as follows Sequence Step LED s on Length Min Max Avg 1 Minute Fill Cycle LED4 60 sec Harvest Cycle LED1 4 amp 2 2 min 20 min 3 5 min Freeze Cycle LED1 5 min 60 min 30 35 min Reverse Pump Out LED1 3 amp 2 10 sec 20 sec Factory set LED 1 Comp LED 2 HGV CFM LED3 PM LED4 WV The built in safeties shut down the unit and have alarms as follows 1 every 3 sec High Evaporator Temperature gt 127 F Check for defrost problem stuck HGV or relay hot water entering unit stuck headmaster or sh
21. OCEDURE 28 Repeat the above steps 17 through 29 three more times to rinse thoroughly Note If you do not sanitize the icemaker go to step 9 in b SANITIZING PROCEDURE 56 b SANITIZING PROCEDURE Following Cleaning Procedure 1 Dilute a 5 25 Sodium Hypochlorite solution with water Add 1 5 fl oz of sanitizer to 3 gal of water 2 Remove the Insulation Panel if it is in its usual position 3 Pour the sanitizing solution into the Water Tank 4 Replace the Insulation Panel and the Front Panel in their correct positions Note Make sure that the Control Switch is in the WASH position and the Cleaning Valve is open 5 Turn on the power supply and start the sanitizing process 6 Turn off the power supply after 15 minutes 7 Remove the Front Panel and if necessary the Insulation Panel 8 Drain the Water Tank See the above step 5 in a CLEANING PROCEDURE 9 Replace the removed parts and the Insulation Panel in their correct position 10 Repeat the above steps 17 through 29 in a CLEANING PROCEDURE two times to rinse thoroughly 11 Close the Cleaning Valve 12 Move the Control Switch to the ICE position 13 Replace the Front Panel in its correct position 14 Clean the Storage Bin with water 15 Turn on the power supply and start the automatic icemaking process 57 3 IMPORTANT This icemaker must be maintained individually referring to the inst
22. PORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS Serial M20315D 115 60 1 10A 5 Min Freeze 104 F WT 80 F 20A 20A Ambient Temp F WATER TEMP F 8007 7 9 60 70 271 123 260 118 249 113 80 263 119 246 112 237 108 90 260 118 234 106 224 102 100 259 118 232 105 215 98 Crescent Cube 4 7 lbs 2 16 kg 240 pcs N A 90 70 F 70 50 F 809 8 3 802 7 1 66 28 4 99 36 4 318 136 209 77 22 x 27 3 8 x 30 5 16 560 x 695 x 770 mm Stainless Steel Galvanized Steel Rear Net 151 Ibs 69 kg Shipping 175 Ibs 80 kg Permanent Connection Inlet 1 2 FPT Condenser Inlet 1 2 FPT Outlet 3 4 Condenser Outlet 3 8 FPT 3 8 OD Pipe Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe Pressure Regulator Proximity Switch with Delay Hermetic Model AKA9438ZXA Water cooled Tube in tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 12 oz 340g High 427 PSIG Low 210 PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 WATE
23. R 45 8 REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE WATER COOLED MODEL 46 9 ADJUSTMENT OF WATER REGULATING VALVE WATER COOLED MODEL ONLY ietaces act iota eta edis 47 10 REMOVAL AND REPLACEMENT OF THERMISTOR 48 11 REMOVAL AND REPLACEMENT OF FAN 49 12 REMOVAL AND REPLACEMENT OF WATER 50 13 REMOVAL AND REPLACEMENT OF PUMP MOTOR 50 14 REMOVAL AND REPLACEMENT OF SPRAY TUBES 51 VI CLEANING AND MAINTENANCE INSTRUCTIONS 52 1 PREPARING THE ICEMAKER FOR LONG 52 rat 54 a CLEANING PROCEDURE eerte 55 SANITIZING PROCEDURE desde ta Ct t 57 SOMAINTEENIANIGE Hed dete ta 58 SPECIFICATIONS 1 280 Air cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EX
24. R SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 7 ll GENERAL INFORMATION 1 CONSTRUCTION a 280 Air cooled y SN Inlet oe gt gt gt eS Control Switch Bin Control Thermostat except models with Mechanical Bin Control 77 Condenser Hot Gas Valve Fan Motor Condenser Expansion Valve lt Compressor Drier Float Switch 2 Vm s Control Box Water Pump Mechanical Bin Control except models with Thermostat b KM 280MWH Water cooled Spray Tubes dini Supply Inlet Control Switch 49 3 Bin Control Thermostat except models with Mechanical Bin Control 77 DUE Regulator Expansion Valve Compressor Float Switch Water Pump Mechanical Bin Control except models with Thermostat 2 CONTROLLER BOARD a SOLID STATE CONTROL 1 A HOSHIZAKI exclusive solid state control is employed in Modular Crescent Cubers 2 A Printed Circuit Board hereafter called Controller Board includes a stable and high quality control system 3 All models are pretested and factory adjusted b CONTROLLER BOARD CAUTION 1 Fragile handle very carefully 2 A controller board contains integrated circuits which are susceptible to failure due to static discharge It is es
25. TERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVAPORATOR REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE P C BOARD CIRCUIT PROTECTION COMPRESSOR PROTECTION REFRIGERANT CIRCUIT PROTECTION LOW WATER PROTECTION ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 115 60 1 11 6 A 5 Min Freeze 104 F WT 80 F 20A Ambient Temp F WATER TEMP 70 70 269 122 247 112 219 99 Crescent Cube 4 7 lbs 2 16 kg 240 pcs N A 90 70 F 70 50 F 946 11 7 829 7 4 47 24 3 83 30 8 22 x 27 3 8 x 30 5 16 560 x 695 x 770 mm Stainless Steel Galvanized Steel Rear Net 151 Ibs 69 kg Shipping 175 Ibs 80 kg Permanent Connection Inlet 1 2 Outlet 3 4 3 8 Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Proximity Switch with Delay Hermetic Model AKA9438ZXA Air cooled Fin and tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 12 02 340g High 467 PSIG Low 230 PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin VOLTAGE RANGE 104 127V AMBIENT TEMP 45 100 F WATER SUPPLY T
26. aks with icemaker off See II 2 e CHECKING CONTROLLER BOARD PROBLEM POSSIBLE CAUSE REMEDY 5 No water a Water Supply Line comes from Spray Tubes 1 Water pressure too low and water level in Water Tank too low Check and get recommended pressure Water Pump b Water Solenoid will not start or Valve freeze cycle Dirty mesh filter or orifice and water level in Water Tank too low Clean time is too c Water System short 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 Capacitor Replace Defective or bound impeller Replace and clean Mechanical Seal worn out Check and replace e Controller Board 6 Fan Motor will Fan Motor not start or is not operating Defective Motor winding opened See 1 2 e CHECKING CONTROLLER BOARD Replace Bearing worn out Replace 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 components Refrigerant run but no ice is produced D
27. e 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 Junction Box Cover from the remote condenser unit Remote Air cooled model 4 Remove the closed end connectors from the Fan Motor leads 5 Remove the Fan Motor Bracket and Fan Motor 49 6 Install the new Fan Motor and replace removed parts in the reverse order of which they were removed 7 Replace the panels in their correct positions 8 Replace the Junction Box Cover in its correct position Remote Air cooled model 9 Turn on the power supply 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
28. e the Insulation Tube and disconnect the Evaporator Inlet Tubing at the 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 For air cooled and water cooled models see the Nameplate for the required refrigerant charge For remote air cooled models see the Charge Label in the machine compartment 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 45 8 REMOVAL AND REPLACEMENT 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 Bracket 8 Install the new valve and braze the Capillary Tube 9 Install the new Drier 10 Check for leaks using nitrogen gas
29. ed 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 Water 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 Coil winding opened Replace f Start Capacitor or Run Capacitor Defective Replace 9 Magnetic Contactor Bad contacts Check for continuity and replace 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 4 Water a Water Solenoid continues to Valve be supplied in b Controller Board freeze cycle Defective Diaphragm does not close Defective See 1 2 e CHECKING CONTROLLER BOARD Check for water le
30. ed 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 7 F the Thermistor operates the High Temperature Safety This High Temperature Safety shuts down the circuit and the icemaker automatically stops This High Temperature Safety protects the unit from excessive temperature The Control Board will Beep every 3 seconds The white Reset Button on the Control Board must be pressed with power on to reset the Safety 4 Low Water Safety If the Pump Motor is operated without water the mechanical seal can fail To prevent this type of failure 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 This method allows for a Low Water Safety shut down to protect the Water Pump from mechanical seal failure For water cooled model if the water is shut off the unit is protected by the
31. ee chart 1 3 and check dirty Air Filter or Condenser ambient or water time is long 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 or Expansion Valve 4 ABNORMAL ICE PROBLEM POSSIBLE CAUSE REMEDY 1 Small Cube a Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin b See chart 1 5 and check water supply line Water Solenoid Valve water system Pump Motor or Controller Board c Drain Valve 1 Dirty 2 Cloudy See chart 2 1 and 3 and check Float Switch Water Solenoid Valve irregular cube Controller Board Spray Tubes water system refrigerant charge or Expansion Valve b Spray Guide 1 Dirty 1 Clean c Water Quality 1 High hardness or contains 1 Install a water filter or impurities softener 5 OTHERS PROBLEM POSSIBLE CAUSE REMEDY 1 Icemaker will Bin Control 1 Set too cold Adjust warmer not stop when Thermostat 2 Defective 2 Replace bin is filled with ice For mechanical bin control 2 Abnormal a Pump Motor Bearings worn out Replace noise b Fan Motor Bearings worn out Replace
32. efective Undercharged See 1 2 e CHECKING CONTROLLER BOARD Check for leaks and recharge 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 in 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 35 Check and get recommended pressure 2 EVAPORATOR IS FROZEN PROBLEM POSSIBLE CAUSE 1 time is too long 2 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 2 Float does not move freely 2 Clean or replace b Water Solenoid Valve Diaphragm does not close Check for water leaks with icemaker off Controller Board a Evaporator Defective Scaled up See 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 Diaphragm does not close Chec
33. er line Bin Control 8 Open Switch for Board Indicate which and ALPINE Board Relays are energized Service Boards only Control Products HOS 001A Board 13 Transformer Connector c SEQUENCE 1st Cycle 1 Unit energized and Control Switch to ICE 3 Thermistor reads 48 F position Water supply cycle starts Defrost Timer starts counting 2 After 1 minute Defrost cycle starts WATER VALVE WATER VALVE HOT GAS VALVE FREEZE PUMP amp FAN amp LINE VALVE 5 Afterthe first 5b 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 freeze cycle IMPORTANT 1 Board never accepts defrost completion signal within the first 2 minutes in defrost cycle 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 14 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 2 Drain timer stops counting freeze cycle Pump drain is completed Drain timer starts counting DRAIN PUMP HOT GAS VALVE rz rS sz DEFROST 3 Thermistor reads 48 F Defrost Timer starts counting Qc
34. he following harvest cycle before shutting down the machine This will prevent incomplete batches of ice from forming on the evaporator 22 TROUBLESHOOTING MECHANICAL BIN CONTROL ONLY 1 Machine will not start i Move dip switch No 7 to the OFF position If the machine starts up within a few seconds the bin control is the likely problem If the machine does not start up refer to Section IV Service Diagnosis to verify that non bin control related issues are resolved ii Check to make sure shipping tape has been removed and the wires are connected properly iii Check to make sure no obstruction prevents the lever from moving to the bin empty position 2 Machine will not shut off i Refer to Section IV Service Diagnosis to verify that non bin control related issues are resolved ii Dip switch No 7 should be in the on position If the switch is in the off position the controller board will not receive input from the bin control iii Move the lever to the far right a If the machine does not shut off check the resistance values of the resistor wire harness You should read approximately 15 8 between the black terminal and the red terminal that connect to the K4 connector on the control ler board when the lever is in the bin full position far right If this reads approximately 7 9 the resistors may be miswired Switch the black and white wires in the terminal housing or order a replacemen
35. hould be none 2 3 4 1 and 4 normal sequence every 5 seconds S3 should remain in the OFF position for normal operation 3 MECHANICAL BIN CONTROL THESE INSTRUCTIONS NOT APPLICABLE TO MODELS WITH THERMOSTAT PROXIMITY SWITCH 1 This machine uses a lever actuated proximity switch hereafter called mechanical bin con trol to control the ice level in the storage bin b EXPLANATION OF OPERATION 1 The startup and shutdown of the ice machine is controlled via the controller board Dip Switch number 7 must be in the ON position for the controller board to receive input from the bin control i The controller board receives a resistance value input via the red K4 connector from the bin control A resistor wire harness is connected from the bin control to the controller board ii When the bin control is activated in the bin full position pushed to the right a 15 8 KQ signal will be sent to the control board to shut down the unit iii When the bin control is in the normal position bin is not full a 7 9 reading is sent to the control board to continue operation 2 During operation the controller board will only shut down the machine if a 15 8 signal is received from the bin control during the first 5 minutes of the freeze cycle i If ice pushes the lever to the right after the first five minutes of the freeze cycle the controller board will allow the machine to complete the freeze cycle and t
36. ine 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 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the Nameplate for the required refrigerant charge For remote air cooled models see the Charge Label in the machine compartment 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 and length when replacing the hot gas lines otherwise the performance may be reduced 43 Always install 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
37. k for water leaks with icemaker off d Ambient and or water temperature Too cool Increase temperature e Line Valve Continues to open in harvest cycle Check operation in harvest cycle and replace f Thermistor Out of position or loose attachment See V 10 REMOVAL AND REPLACEMENT OF THERMISTOR g Controller Board a Spray Tubes Defrost Timer is set too short Adjust longer referring to Il 2 d CONTROLS AND ADJUSTMENT 2 Defrost Timer Defective Clogged See Il 2 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 Coil winding opened Replace Plunger does not move Replace Wiring to Hot Gas Valve Check for loose connection or open and replace f Water Supply Line Too small requires 3 8 OD line dedicated per machine Increase Water Line size 9 Water Filter if installed Flow rate too small 36 Replace with filter with larger flow rate 3 LOW ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY 1 Freeze cycle a S
38. l position To Freeze Cycle From Freeze Cycle ey Temp Low Temp Defrost include drain Thermistor Temp ON Float Switch Compressor Heater wn q 2 93 2 lesmak 1 as Pump Motor 1 c A Dr bs 5 5 i 1 Pan Motor amp Line Velve Fan Motor Condeneer Usit ovr Max E 2 Hot Gas Velve 71 Pump Motor waits for 2 seconds before starting a drain cycle See Il 2 d CONTROLS ADJUSTMENTS Ir i 0 min 2 The icemaker does not complete a defrost cycle in the first 2 or minutes See 2 d CONTROLS AND ADJUSTMENTS 3 Mechanical bin control only The bin control will only shut off the ice machine during the first five minutes of the freeze cyle 29 4 PERFORMANCE DATA a KM 280MAH APPROXIMATE ICE AMBIENT TEMP PRODUCTION PER 24 HR 50 10 70 21 70 21 1 11 80 27 90 32 Ibs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day m day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg c
39. limited to 20 minutes even if Defrost Timer does not stop counting 16 d CONTROLS AND ADJUSTMENTS The Dip Switch is factory adjusted to the following positions FOR MODELS WITH MECHANICAL BIN CONTROL DIP SWITCH NO KM 280MAH KM 280MWH FOR MODELS WITH THERMOSTAT DIP SWITCH NO KM 280MAH KM 280MWH 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 determined by the Drain Timer The Drain Timer also determines the time to restrain completion of a defrost cycle i e the minimum defrost time Switch Nos 5 and 6 Used for adjustment of the Drain Counter The Pump Motor drains the Water Tank at the frequency determined by the Drain Counter Switch No 7 Used only on models with mechanical bin control Dip Switch should be set Models with bin thermostat Switch No 7 should be set in the OFF position Switch No 8 Used only for checking the Controller Board Usually set in OFF position 17 Freeze Timer Control Board Check only ES Mechanical Bin Control Used for adjustment
40. ly 41 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 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the Nameplate for the required refrigerant charge For remote air cooled models see the Charge Label in the machine compartment 8 Replace the panels in their correct positions 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 supply 2 Remove the panels 42 3 Recover the refrigerant and store it in an approved container 4 Remove the insulation and the Expansion Valve Bulb on the suction l
41. m G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 8159 BTU h AT 90 F 32 C WT 70 F 21 C Note Pressure data is recorded at 5 minutes into freeze cycle The data not in bold should be used for reference only We reserve the right to make changes in specifications and design without prior notice 30 b KM 280MWH Serial 100001 M10134C APPROXIMATE ICE AMBIENT TEMP 70 21 80 27 90 32 Ibs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 6573 BTU h AT 90 F 32 WT 70 F 21 C TOTAL HEAT OF REJECTION FROM COMPRESSOR 1386 BTU h AT 90 F 32 WT 70 F 21 C WATER FLOW FOR CONDENSER 30 4 gal h 100 F 38 C WT 90 F 32 C PRESSURE DROP OF COOLING WATER LINE less than 10 PSIG Note Pressure data is recorded at 5 minutes into freeze cycle The data not in bold should be used for reference only We reserve the right to make changes in specifications and design without prior notice 31 c KM 280MWH Serial M20315D APPROXIMATE ICE AMBIENT TEMP WATER TEMP F C PRODUCTION PER 24 HR
42. n MAH ERA 412 3 PSIG 327 21 PSIG BIN CONTROL ONLY AIR COOLED MODEL ONLY WATER COOLED MODEL MWH Cut out 384 Cut in 284 21 26 PSIG PSIG KM 280MAH with auxiliary codes M 2 and after and KM 280MWH with auxiliary codes M 2 and after FUSE BIN CONTROL CONTROLLER THERMISTOR I5 oie tt lt gt 115 1701601 ONLY AIR COOLED MODEL ONLY WATER COOLED MODEL 27 3 TIMING CHART When Control Sw is turned OFF Pressure Sw is OFF Thermistor Temp exceeds t1 or Bin Control is full position during first 5 minutes of freeze cycle for mechanical bin control only 3 From Defrost Cycle Jo Defrost Cycle If Float Sw loi t ial Defrest Freeze Thermistor gt ee be os Pump Motor is OFF breil Pan Motor ON amp Line Valve om 1 Condesser Unit 91 Hot Gas Valve pal ae 1 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes See Il 2 d CONTROLS AND ADJUSTMENTS 3 Mechanical bin control only The bin control will only shut off the ice machine during the first five minutes of the freeze cyle 28 To Stand by Cycle When Control Sw is turned OFF Pressure Sw OFF Thermistor Temp exceeds ti or Bin Control is in ful
43. of Freeze Timer Drain Counter ccr d The Freeze Timer determines maximum freeze cycle time Upon termination of Drain Timer 7 NE C Freeze Timer machine initiates the harvest cycle After 2 consecutive timer terminations machine will shut down possibly indicating a problem Switch Nos 9 and 10 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 necessary check for resistance between Thermistor leads and visually check the Thermistor mounting located on the Suction Line next to the Evaporator outlet Temperature Resistance 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 10 REMOVAL AND REPLACEMENT OF THERMISTOR iii Immerse the Thermistor sensor portion a glass containing ice and water for 2 or minutes iv Check for a resistance between Thermistor leads Normal reading is within 3 5 to 7 Replace the Thermistor if it exceeds the normal reading 2 Defrost Timer No adjustment is required under normal use as the Defrost Timer is adjusted to the suitable position However if necessary when all
44. onnection Inlet 1 2 FPT Condenser Inlet 1 2 FPT Outlet 3 4 Condenser Outlet 3 8 FPT 3 8 OD Pipe Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe Pressure Regulator Proximity Switch with Delay Hermetic Model AKA9438ZXA Water cooled Tube in tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 12 2 340g High 427 PSIG Low 230 PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin VOLTAGE RANGE 104 127 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 2b KM 280MWH Water cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Reference without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W kWH 100 lbs WATER gal 24HR gal 100 lbs WATER COOLED CONDENSER gal 24HR gal 100 Ibs EXTERIOR DIMENSIONS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC WATER SUPPLY DRAIN CUBE CONTROL SYSTEM HARVESTING CONTROL SYSTEM ICE MAKING WATER CONTROL COOLING WATER CONTROL BIN CONTROL SYSTEM COMPRESSOR CONDENSER EVA
45. orted thermistor 2 beeps every 3 sec Defrost Back Up Timer Defrost gt 20 minutes Orange LED marked 20 MIN energizes Check for open thermistor HGV not opening TXV leaking by low charge or inefficient compressor 3 beeps every 3 sec Freeze Back Up Timer Freeze 60 minutes Yellow LED marked 60 MIN energizes Check for F S stuck closed up WV leaking by HGV leaking by TXV not feeding properly low charge or inefficient compressor 4 beeps every 3 sec Short Circuit between the K4 connection Machines the control board and the bin control relay Check connections and with replace wire harness if necessary mechanical bin control ONLY 5 beeps every 3 sec Open Circuit between the K4 connection on the control board and the bin control relay Check connections and replace wire harness if necessary To manually reset the above safeties depress white alarm reset button with the power supply ON 6 beeps every 3 sec Low Voltage Voltage is 92 Vac or less 7 beeps every sec High Voltage Control voltage gt 147 Vac 595 The red LED will de energize if voltage protection operates The voltage safety automatically resets when voltage is corrected The Output Test switch S3 provides a relay sequence test With power OFF place S3 ON and switch power to ICE The correct lighting sequence should be none 2 3 4 1 amp 4 normal sequence every 5 seconds S3 should remain in the OFF
46. osition Disconnect the Thermistor from the Controller Board Connect a 1 5 3 5 resistor to the Connector pins 1 and 2 and energize the unit After the 1 minute 5 second water supply cycle and the 2 minute 10 second defrost cycle the unit should start the freeze cycle 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 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 Reconnect a 1 5 3 5 resistor to the Connector pins 1 and 2 after the first 2 minutes of the defrost cycle The unit should start the freeze cycle after 1 minute 5 seconds from the resistor connection 21 3 Check the Controller Board by using test program of the Controller Board The Output Test Switch 53 provides a relay sequence test With power OFF place S3 on and switch power to ICE The correct lighting sequence s
47. ot mix lubricants of different compressors even if both are charged with R 404A except when they use the same lubricant 1 Turn off the power supply 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 7 Slide and remove the Compressor Unpack the new Compressor package Install the new Compressor 8 Attach the Rubber Grommets of the prior Compressor 9 Sandpaper the Suction Discharge 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 Filter Drier 14 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 40 15 Evacuate the system and charge it with refrigerant For air cooled and water cooled models see the Nameplate for the required refrigerant charge For remote air cooled models see the Charge Label in the machine compartment 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 supp
48. ow the water cooled Condenser out using compressed air or carbon 2 Remove the water from the potable water supply line 1 Remove the Front Panel Except water cooled model 2 Move the Control Switch on the Control Box to the OFF position 3 Wait 3 minutes 4 Close the Potable Water Supply Line Shut off Valve and open the Potable Water Supply Line Drain Valve 5 Allow the line to drain by gravity 6 Attach compressed air or carbon dioxide supply to the Potable Water Line Drain Valve 7 Move the Control Switch to the position 8 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 Move the Control Switch to the OFF position 3 Drain the Water Tank by removing the base cover and one end of the pump tubing See Fig 4 4 Replace the removed parts in their correct positions 5 Remove all ice from the Storage Bin and clean the Storage Bin 6 Replace the Front Panel in its correct position 7 Close the Drain Valve 53 Pump Tubing Do not pull out this side Fig 4 2 CLEANING IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment WARNING HOSHIZAKI recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water condi tions
49. pecially 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 Do not misconnect K3 K4 and K5 because the same connector is used for the Thermistor white Float Switch black and Mechanical Bin Control red For machines with thermostat there is no connection on K4 5 Always replace the whole board assembly when it goes bad 6 Do not short out power supply to test for voltage PART NUMBER TYPE 2 1410 01 5 00 Control Products Features of Control Products Controller Board 1 Maximum Water Supply Period 6 minutes Water Solenoid Valve opening in the Defrost Harvest Cycle is limited by the defrost timer The Water Valve cannot remain open longer than the maximum period The Water Valve can close in less than six minutes if the defrost cycle is completed 10 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 Thermistor senses 48 F at the Evapora tor outlet The period from the end of the freeze cycle up to the point of the Thermistor s sensing varies depending on the ambient and water temperatures 3 High Temperature Safety 127 7 F The temperature of the suction line in the refrigerant circuit is limit
50. ruction manual and labels provided with the icemaker 1 Stainless Steel Exterior To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up 2 Storage Bin and Scoop Wash your hands before removing ice Use the plastic scoop provided The Storage Bin is for ice use only Do not store anything else in the bin Keep the scoop clean Clean it by using a neutral cleaner and rinse thoroughly Clean the bin liner by using a neutral cleaner Rinse thoroughly after cleaning 3 Condenser Except water cooled model 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 58
51. t wire harness b Check the stainless steel bracket that the bin control is mounted to c If the preceding items do not resolve the problem replace the Bin Control Assembly 23 Ill TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT a3 KM 280MAH Spray Tube Condenser Water High Pressure Switch N Water E 33101724932 82088911002 Sue jq i Evaporator 1 iid j Thermistor Insulation j Strainer yu Hot G Valve m J C Discharge Line Compressor L Refrigerant Circuit Expansion Valve wm Water Circuit Drain Valve 24 b KM 280MWH Condenser Water Regulating Valve Spray Tube Water i Drain w N Water Water enm y Supply fH 16 i w rm Supply Ema ME Evaporator Drier High Pressure Switch Cleaning CI Thermistor i Valve i Insulation Tube Strainer ii enetina Y Hot Gas Suction Valve Line EE Discharge Line Compressor Refrigerant Circuit Expansion Valve mE Water Circuit Drain Valve 25 2 WIRING DIAGRAMS a KM 280MAH with auxiliary codes L 0 M 0 and M 1 and KM 280MWH with auxiliary codes L 0 M 0 and M 1 START 378 445MF0 Note Pressure Switch Cut out Cut i
52. their correct positions 8 Pour the cleaning solution into the Water Tank 9 Fully open the Cleaning Valve on the left side wall of the machine compartment 10 Move the Control Switch on the Control Box to the WASH position 11 Replace the 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 and the Insulation Panel 15 Drain the Water Tank See the above step 6 16 Replace the removed parts in their correct positions 17 Move the Control Switch to the ICE position 18 Close the Cleaning Valve Note The icemaker will not operate unless the Cleaning Valve is completely closed 55 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 and fully open the Cleaning Valve 23 Move the Control Switch to the Wash position 24 Replace the Front Panel in its correct position 25 Turn on the power supply to rise off the cleaning solution 26 Turn off the power supply after 5 minutes 27 Remove the Front Panel and Insulation Panel 28 Drain the Water Tank by removing one end of the Pump Tubing See Fig 4 29 Replace the removed parts in their correct positions Note Do not replace the InsulationPanel when you proceed to 10 SANITIZING PR
53. tself is not flammable at atmospheric pressure and temperatures up to 176 Refrigerant R 4044 itself is not explosive or poisonous However when exposed to high temperatures open flames R 404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous Always recover the refrigerant and store it in an approved container Do not discharge the refrigerant into the atmosphere Do not use silver alloy or copper alloy containing Arsenic Do not use R 404A as a mixture with pressurized air for leak testing Refrigerant leaks can be detected by charging the unit with a little refriger ant raising the pressure with nitrogen and using an electronic leak detector Note All brazing connections inside the Evaporator Case are clear paint coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove coating 39 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 new Start Capacitor and Start Relay supplied with the replacement Compressor Due to the ability of the POE oil in the compressor to absorb moisture quickly the Compressor must not be opened more than 15 minutes for replacement or service Do n
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