KM50A Service Manual
Contents
1. 2 SPECIFICATIONS a KM 30A KM 35A AC SUPPLY VOLTAGE 1 PHASE 220 240V 50Hz AMPERAGE 1 5 AT 32 C WT 21 C STARTING AMPERAGE 10 0A ELECTRIC CONSUMPTION 195W AT 32 C WT 21 C POWER FACTOR 54 POWER SUPPLY CAPACITY Min 0 65KVA 2 73A Approx 36kg AT 10 C WT 10 C ICE PRODUCTION PER 24h Approx 32kg AT 21 C WT 15 C Approx 25kg AT 32 C WT 21 C Approx 0 142m AT 10 C WT 10 C WATER CONSUMPTION PER 24h Approx 0 060m AT 21 C WT 15 C Approx 0 042m AT 32 C WT 21 C SHAPE OF ICE CRESCENT CUBE FREEZE CYCLE TIME Approx 30min AT 21 C WT 15 C ICE PRODUCTION PER CYCLE Approx 0 71kg 80pcs AT 21 C WT 15 C MAX STORAGE CAPACITY Approx 16kg Bin Control Setting Approx 14kg DIMENSIONS DRAWING Ne 450mm W x610mm D x842mm H 003921 EXTERIOR Stainless Steel Galvanized Steel Rear INSULATION Polyurethane Foam CONNECTIONS ELECTRIC Y type Con with CONT Plug ELECTRIC European Model X type Con With Plug WATER SUPPLY Inlet G3 4 connected at rear side DRAIN Outlet 25 connected at rear side ICE MAKING SYSTEM Vertical Evaporator with water flow on both sides COMPRESSOR Hermetic 125W Model QA51K13GAW5 HOLE CONDENSER Air cooled Fin and Tube type HEAT REJECTION 460W 394kcal h AT 32 C WT 21 C EVAPORATOR Vertical type Stainless Steel and Copper REFRIGERANT CONTROL Capillary Tube REFRIGERANT CHARGE R134a 200g ICE MAKING CONTROL SYSTEM Float Switch HAR2. 29 IV SERVICE DIAGNOSIS 30 1 NO ICE PRODUCTION 30 2 EVAPORATOR IS FROZEN 32 LOW ICE PRODUCTION 33 4 ABNORMAL 33 5 34 V REMOVAL AND REPLACEMENT 35 1 SERVICE FOR REFRIGERANT LINES 35 a SERVICE INFORMATION 35 b REFRIGERANT RECOVERY 36 ZN 37 S COMPRESSOR a uq 38 Eee een eee 39 HOT GAS WI 40 6 EXPANSION VALVE KM 75A 42 MOTOR PME MEME 44 B PUMP MOTOR 45 S WATER RN 46 NC E ttt eee 47 UM FLOAT E END 48 3 KM 30A KM BSA KI 5 0A iii neat 48 ij B
3. 49 12 BINLCONTROL SWITO eee edad pius 50 15 THERMISTOR i tea 53 14 CONTROLBOX asse ii ili lil li ili l i i l l i sa aa 54 POWER SUTO asics aa 55 6 55 o FUSE HOLDER end u 55 d CONTROL BOARD 55 E POWER RELAY ee 55 COMPRESSOR CAPACITOR 50 KM 75A ONLY 56 9 CONTROL BOARD 5 56 15 WATER de X 56 16 CUBE a ree acon nt nn ta ees ne essere 58 17 SEPARATOR setae a 59 18 SPRAY TUBE WATER SUPPLY PIPE SPRAY GUIDE 59 19 DOOR 60 CLEANING AND MAINTENANCE INSTRUCTIONS 61 12 CLEANING MM 61 a CLEANING PROCEDURE 61 b SANITIZING PROCEDURE ceca u a usss 63 2 MAINTENANCE u a ee 64 3 EXTERIOR a 64 b STORAGE BIN AND SCOOP soe 64 FILTER eee 64 X 64 3 PREPARING THE ICEMAKER FOR LONG STORAGE 64 I SPECIFICATIONS 1 DIMENSIONS CONNECTIONS 1 ES a KM 30A KM 35A zl E lt lt Unit mm WATER DRAIN 625 MALE b KM 35A Auxiliary code V 1
4. Ajddns UO pue YOUMS J0 u02 peeoxe sejo o 10119 92989JJ e o o ezeeJ 02 23 U91IMS SS 1d Jo uo dwe 99 c sdeeq 2 16 go uo sjo9jep Jojsiuueu 999 pusa J MOd SIUM U91IMS 1959 SS9Jd 34O peo Jezzng popJoooi JOJJ3 UOnIpuoo JOS UI 0 995 sd uO QWE 1 N 5 46 1soJjop 1soJjJeq OML 99 1012 sjoejep JoyeJodeAe JOSIWUBY gt AO 9q UMOUS S eJeu uonipuoo 1011 ue sjueseJdeJ eouenbes 22 4 un y dols pue 1esn y o Jezznq e punos pieog jonuoo esneo e 10 jouueo yun y JI SWYV Iv f CHECKING THE CONTROL BOARD Before replacing a Control Board that does not show a visible defect and that you suspect is bad always conduct the following check procedure This procedure will help you verify your diagnosis 1 Check the Dip Switch settings to assure that 3 4 7 8 9 amp 10 are in the factory default position Switch
5. Dau gt 523 GR oA 0 24 los WIRE COLOR ie CODE TAN 2 1 BR BROWN MOTOR WATER 91 KT Lm 2 ORANGE D iw s a BU BLUE u G Y GREBN TRLLOW WIRING DIAGRAM KM 50A 5 FLOAT CONTROLLER WITH PY FUSE s s 19 5A Qm 5 SMITH 1l OSE SUPPRESSION RT D m A VII sese PENIS QD s 010 BR SHE DE OO I i iu PROTECTOR POVER RELAY mm cw R DBu E START 05 a 220 240 50 1 Cap 2 O 1 017 DT 1 ES BK E W gt 102 4 93 ag 0 WIRE COLOR los CODE FAN js MORI S WATER BK BLACK VALVE VAL ORANGE By ore D A Li BU BLUE v n DBu DARK BLUE a LIGEL BLUS BR G Y GREEN YELLOW To BR bf 28 29 330 NO 9x Avi3H sum 440 jo 330 Wd 8 NO 5 w 9 330 W3 AH NO 330 NO IX AVI38 n HOLIMS a 1O31NOONI 998 06 gt 4 295 GL 440 NO HOLMS 1VO13 440 09502 gt m 9559 gt 440 SATA H31VM 9 Xe uUngxewNja 9 XEN 9
6. 9 xew mu ieri AWA SVO LOH T T T 1 T T 0918110 Z A 330 epoo Aueixny jo ett kanaa e 96306 2950 6 gt 2 506 2950 gt i 4 gt 29506 28501 4 0 lt 29505 i 2 L s poO Le 4 9 uejxnv Jo SOLON Nv4 NOSS3HdWOO YOLSINYSHL HOLIMS 40 lio aoho somey V 48 sete ui 98s 05 unu g kam uu 295 og g oi 9 Jaye 2 6 Sesues iojstuay 8 OM 0P 9 6 sosues TIDA sg 31040 1 1113 81049 LSAAYVH 31040 323344 TOKO LSSASVE 31040 323344 31949 1S3ANVH 31040 3z33u4 ATSINNA 19d ASTRA 31040 LSIAYVH IV SERVICE DIAGNOSIS 1 NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY 1 The icemaker a Power Supply 1 OFF position 1 Move to ON position will not start 2 Tighten replace L commendedvotage voltage 5 5 Unplugged _______ 5 b Plugin in if an replace c Control Switch replace with ice replace or coil winding opened 9 Thermistor 1 Leads shorted or open 1 See Il 2 d CONTROLS and High Temperature AND ADJUSTMENTS 2 Safety operates If Defrost Control open unit will start
7. HOSHIZAKI SELF CONTAINED MODEL KM 30A KM 35A KM 50A KM 75A SERVICE MANUAL CONTENTS PAGE SPECIFICATIONS 1 1 DIMENSIONS CONNECTIONS 1 a KM 30A 35 1 b KM 35A Auxiliary code V 1 or later European model only 2 c KM 50A 3 d KM 50A Auxiliary code V 1 or later European model only 4 e 5 f KM 75A Auxiliary code V 1 or later European model only 6 2 SPECIFICATIONS o ee en nenne nn nnn enn nnm mL M 7 a KM 30A 35 7 b 50 8 c KM 75A 9 Il GENERAL INFORMATION 10 1 CONSTRUCTION 10 a KM 30A KM 3
8. 2 Defrost Control A thermistor Semiconductor is used for the 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 F Temperature C Resistance Check the Thermistor for resistance by using the following procedures i Disconnect the Connector K1 on the board ii Remove the Thermistor See V 13 THERMISTOR iii Immerse the Thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes iv Check for resistance between the Thermistor leads Normal reading is within 3 5 to 7 kilohms Replace the Thermistor if it exceeds the normal reading 3 Defrost Timer No adjustment is required under normal use as 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 defrost cycle adjust the Defrost Timer to longer position by setting the Dip Switch Nos 1 amp 2 on the Control Board Dip Switch Setting Time seconds factory adjustment 6 ON OFF 9 4 Drain Counter The Drain Counter is factory adjusted to drain the Water Tank every 10 cycl
9. 6 Attach the new Float Switch to the Rail of the Bracket Secure them with the screw by fitting the round end of the slot to the screw hole When fitted properly top ends of Bracket and Float Switch become flush with each other Secure here with screw Screw Fig 14 49 7 Put the Float Switch down into the mounting hole and hook it in position as shown To ensure proper operation be sure to fit the Hook A under the mounting hole 8 Refit the removed parts in the reverse order of the removal procedure 9 Plug in the icemaker or connect the power source Mounting Hole Fig 15 12 BINCONTROL SWITCH 1 Unplug the icemaker or disconnect the power source 2 Remove the Top Panel and unscrew the Rear Panel 3 Disconnect the Connector of the Bin Control Switch lead black covered with a silicone hose and remove the lead wire from the Grommet 4 Remove the Water Tank see 15 WATER TANK The Bin Control Switch is located as shown below when viewed from the front Separator Bin Control Switch Fig 16 5 Pull down and remove the lead wire from the retainer on the right side of the Bin Control Switch 6 Hold both sides of the Bin Control Switch and pull it toward you 50 Retainer Pump Motor D Slide Rail both sides Stopper A both sides Fig 17 7 The Bin Control Switch KM 30A 35A pulled out of the Storage
10. LED 5 X1 Relay Compressor LED 6 X2 Relay Hot Gas Valve Fan Motor Fan Motor off when LED on Connector K3 Magnetic Contactor Connector K4 Open LED 8 X4 Relay POWER OK LED Water Valve Lights when power is supplied to the board Flashes when bin control is activated Connector K5 Pins 1 Fan Motor 2 Hot Gas Valve 3 Pump Motor 4 Water Valve 5 Open 6 Drain Valve LED 4 X6 Relay Drain Valve LED 7 X3 Relay Pump Motor Connector K6 Open Connector 8 O Connector K1 i Pins 1 3 Float Switch Output Test Button 22 Open used to test relays on 4 5 Bin Control 6 7 Thermistor 8 9 Open board 1 10 22 2 Alarm Buzzer Dip Switch Alarm Reset Button pen Control Board Auxiliary Code Factory Part Number Service Part Number Type 19 d CONTROLS AND ADJUSTMENTS 1 Dip Switch The Dip Switches on the Control Board are factory adjusted to the following positions M amp moe CAUTION Do not change the settings of the Dip Switch Nos 3 4 7 8 9 and 10 or the unit will not operate properly If the S2 Dip Switch is mounted on the Control Board all should be left in the OFF position 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 S
11. Move the Control Switch to the ICE position to fill the Water Tank with water 9 After 3 minutes move the Control Switch to the WASH position 10 After 5 minutes move the Control Switch to the OFF position 11 Same as step 4 12 Repeat steps 8 through 11 three more times to rinse thoroughly 13 Disconnect the Silicone Hose and Overflow Pipe Remove the Water Tank See V 15 WATER for details 14 Pull the Cube Guides quantity varies depending on model upward to remove them from the Water Tank They are snapped in place See Fig 30 Refer to V 16 CUBE GUIDE for details Cube Guide Water Tank V This illustration shows KM 30A 35A The following number of Cube Guides are provided KM 30A 35A 2 pcs KM 50A 3 pcs KM 75A 3 pcs The Bin Control Switch is accessible by removing the Water Tank Pull the switch towards you for easy maintenance This is the front view with the Door opened and the Water Tank removed Bin Control Switch Fig 30 62 15 Same as step 1 16 Wash the Bin Control Switch Water Tank Float Switch Cube Guide Silicone Hose and Overflow Pipe by using a nylon scouring pad brushes and the cleaning solution In addition to the removed parts also wash the bin liner and Bracket L R with the solution 17 Discard the cleaning solution and rinse the parts thoroughly with water b SANITIZING PROCEDURE Foll
12. 1 Diaphragm does not 1 Check for water leaks continues to be Valve close with icemaker off supplied in Replace if necessary freeze cycle 1 See Il 2 f CHECKING THE CONTROL BOARD 5 No water a Water Supply Line 1 Water pressure too low 1 Check and get comes from and water level in Water recommended pressure Spray Tubes Tank too low Water Pump b Water Solenoid 1 Dirty mesh filter or 1 Clean will not start or Valve orifice and water level in freeze cycle Water Tank too low short water leaks and replace d Pump Motor 1 Motor winding opened 3 Wiring to Pump Motor 3 Check for loose connection or open and replace 4 Defective Capacitor 5 Defective or bound 5 Replace and clean impeller 31 PROBLEM POSSIBLE CAUSE REMEDY 5 Continued e Control Board 1 Defective 1 See Il 2 f CHECKING THE CONTROL BOARD 6 Fan Motor will a Fan Motor 1 Motor winding opened not start or is not operating 3 Wiring to Fan Motor 3 Check for loose connection or open and replace 4 arp EN blade bound 4 Check and replace arp EN Fan Motor b Control Board 1 B e 1 See Il 2 ff CHECKING run but no ice is recharge recharge 1 Defective valve Hot Gas Solenoid 1 Continues to open in 1 Check and replace Valve freeze cycle 2 EVAPORATOR IS FROZEN UP PROBLEM POSSIBLE CAUSE REMEDY 1 Freeze cycle a Float Switch 1 Leads shorted or 1 Check a
13. Bin has the internal structure as shown below Reed Switch Lead Hook Stopper B both sides Fit in Stopper A Bin Switch Case Bin Switch Plate Reed Switch Cover Fig 18 51 8 To remove the Bin Switch Plate slightly warp both sides and pull the Shaft toward you Slightly warp b Pull toward you Top View Fig 19 9 Refit the removed parts in the reverse order of the removal procedure Be sure to put the lead wire back in the Retainer on the Bracket 10 Plug in the icemaker or connect the power source 52 13 THERMISTOR 1 Unplug the icemaker or disconnect the power source 2 Remove the Top Panel and unscrew the Rear Panel 3 Disconnect the Connector of the Thermistor lead orange 4 Remove the Ties Insulation Thermistor Holder and Thermistor in this order 5 Remove the old sealant from the Thermistor Holder and Suction Pipe 6 Wipe off any moisture or condensation from the Suction Pipe surfaces 7 Press a tube of the sealant KE4560RTV manufactured by Shin Etsu Silicones to the recess of the Thermistor Holder Slowly squeeze the sealant out of the tube and spread it smoothly in the recess Do not use any sealant other than the above 8 Attach the new Thermistor in position on the Suction Pipe and press down the Thermistor Holder over the Thermistor Be careful not to damage the Thermistor lead Cover the parts with the Insu
14. Evaporator surface At 5 minutes after thermistor temperature 4 Defrost Timer stops counting Defrost cycle reaches 2 C in freeze cycle Ready to is completed and freeze cycle starts complete freeze cycle when Float Switch IMPORTANT circuit opens 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 after thermistor temperature reaches 2 C 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 15 2nd cycle and after Drain Valve open IMPORTANT Freeze cycle time is limited to the time set by Freeze Backup Timer on Control Board see Id CONTROLS AND ADJUSTMENTS even if Float Switch does not open Note The Drain Valve is factory adjusted to open every 10 cycles This frequency is adjustable according to the water quality See d 4 Drain Counter for further details 1 Float Switch opens and signals to complete 2 Thermistor reads 9 C Defrost freeze cycle Timer starts counting 6 After the freeze cycle amp completes Drain Valve opens for 20 seconds NY to drain out Water Tank WATER VALVE When Drain Valve closes Water Valve opens and unit resumes normal cycle 4 2 DEFROST CYCLE To prevent slushing Pump Motor stops see 3 TIMING CHART IMPOR
15. SPRAY GUIDE 1 Unplug the icemaker or disconnect the power source Remove the Top Panel 2 Push the Tabs on both sides to release the Spray Tube 3 Remove the end of the Spray Tube from the Bracket 4 Pinch and lower the Hose Clamp and disconnect the Hose The Spray Tube is easily cleanable by removing the black rubber cap on the end 59 5 The Water Supply Pipe is located right under the Spray Tube Remove the Water Supply Pipe from the Evaporator pinch and shift the Hose Clamp and disconnect the Hose 6 The Spray Guide is located under the Water Supply Pipe Pull off the Spray Guide from the Evaporator Plate 7 Refit the removed parts in the reverse order of the removal procedure Check for water leaks IMPORTANT Fit the Spray Guide securely and tightly on the Evaporator fin Otherwise cloudy or irregular ice cubes or performance reduction may be caused 8 Plug in the icemaker or connect the power source 19 DOOR 1 Remove the Top Panel 2 Move the Door to fit the Door Shaft in the inlet of the Door Channel Slide up the Door to release it from the Door Channel 3 Refit the Door in the reverse order of the removal procedure Do not forget to fit the Collar on the Door Shaft or the Door will not open or close smoothly Door Channel CLEANING AND MAINTENANCE INSTRUCTIONS IMPORTANT Ensure all components fasteners and screws are securely in place after any maintenance or cleaning is done
16. TECHNICAL INFORMATION 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT a KM 30A KM 35A KM 50A Water Inlet _ _ MEM Water Valve o Capillary Tube id Xx Spray Tube ________ 4 r 2 Thermistor Pump Motor gt 1 Evaporator m Water Tank Float Switch 3 3 lt lt Drain Valve Condenser Compressor Water Circuit Refrigeration Circuit 26 b KM 75A Water Inlet Pump Motor Float Switch Compressor Condenser Water Circuit c Refrigeration Circuit 27 2 WIRING DIAGRAM WIRING DIAGRAM KM 30A KM 35A _ MOT 2 a S 5A CONTRO f d 02 NOISE SUPPRESSION NEUE 191 CAPACITOR 20 480 Bio i 27 a WITH 05921 BR come Le TR Q 10 s PROTECICR PER RELAY LE 3 M 1 6 P DBu o i picis 220 240 50 1 ae BK Romi n lof W gt
17. container if required by an applicable law see 1 5 REFRIGERANT RECOVERY 4 Disconnect the Hot Gas Valve leads 5 Remove the screw and the Solenoid Coil 6 Remove the valve and Drier using brazing equipment Hot Gas Valve 40 7 Braze the new Hot Gas Valve with nitrogen gas flowing at a pressure of 0 2 0 3 bar WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 135 C 8 Install the new Drier see 4 DRIER 9 Check for leaks using nitrogen gas 10 bar and soap bubbles 10 Evacuate the system and charge it with refrigerant see 1 c EVACUATION AND RECHARGE 11 Attach the Solenoid Coil to the valve body and secure it with the screw 12 Connect the lead wires 13 Refit the panels in their correct positions 14 Plug in the icemaker or connect the power source 41 6 EXPANSION VALVE KM 75A ONLY IMPORTANT The water in the refrigeration circuit may exceed the capacity of the Drier and freeze in the Expansion Valve Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Unplug the icemaker or disconnect the power source 2 Remove the Top Panel Rear Panel and Rear Cover 3 Recover the refrigerant and store it in a proper container if required by an applicable law
18. may be removed But be careful not to break the lead wires 2 Remove the mounting screw and lift off the Transformer from the fit at the bottom 3 Install the new Transformer in the reverse order of the removal procedure 15 WATER TANK 1 Unplug the icemaker or disconnect the power source Remove all ice from the Storage Bin 2 Drain out the Water Tank by pulling off the Overflow Pipe from the Water Tank bottom and the Silicone Hose from the Storage Bin bottom Dn N N Cube Guide eec e Water Tank NET Ses WA Silicone Hose 7 Connect disconnect SA arrowed part Ne Overflow Pipe _ C J Disconnect from tank Storage Bin a bottom eee x Vea age SU Fig 22 3 Pinch and push down the Snaps on both sides of the Bracket to unhook the Water Tank from the square holes and pull it about 1 toward you Water Tank Fig 23 4 When the Snaps are unhooked from the square holes the rear part of the Water Tank dotted circle below is also unhooked Hold the Water Tank with both hands Float Switch 5 Tilt the right side of the Water Tank and pull it toward you Do not hit the Pump Motor or Float Switch Slightly twist the left side of the Water Tank inward and pull it toward you Left Side Right Side 57 6 Slide the left si
19. or later European model only Unit mm G3 4 FEMALE WATER INLET POWER SUPPLY CORD 40 12 610 450 386 252 b Z c KM 50A Unit mm WATER INLET POWER SUPPLY CORD 53 47 FEMALE WATER DRAIN 025 MALE a 1402 114415 N3MOd 7 07 31VN34 v7 9 131NI 431VM d KM 50A Auxiliary code V 1 or later European model only Unit mm 3IVN 620 Nivad 431VM GYG 655 09 e KM 75A Unit mm 112 603 POWER SUPPLY CORD WATER DRAIN 25 MALE f KM 75A Auxiliary code V 1 or later European model only Unit mm E Es gt ze 06 2 WATER DRAIN 25 MALE E lt ex o lt gt r Lo lt 068 8t8 603 534
20. see 1 5 REFRIGERANT RECOVERY 4 Remove the Expansion Valve using brazing equipment Protect the Evaporator and pipes from excessive heat with damp cloths or similar 5 Remove the Insulation Hose from the Expansion Valve Sensor Bulb and remove the Bulb 6 Remove the Drier using brazing equipment 7 Braze in the new Expansion Valve Protect the body of the valve from excessive heat and use nitrogen at a pressure of 0 2 0 3 bar when brazing 8 Braze or solder the new Drier see 4 DRIER 9 Check for leaks using nitrogen gas 10 bar and soap bubbles 10 Evacuate the system and charge it with refrigerant see 1 c EVACUATION AND RECHARGE 11 Attach the Bulb to the suction line in position Be sure to secure it using a wire or clamp and replace the insulation 12 Replace the panels in their correct positions 13 Plug in the icemaker or connect the power source WARNING Always protect the valve body by using a damp cloth to prevent the valve from overheating Do not braze with the valve body exceeding 115 C 42 Top Rear View with Top and Rear Panels Removed Remove Expansion Valve Cover first Cut ties to make Bulb removable A NS ANN N UN Bulb Insulation Hose Wrap this part with a Expansion Valve damp cloth to prevent overheating Expansion Valve is brazed at these two points While brazing remove In sulation Hoses fro
21. to the equipment 1 CLEANING WARNING Hoshizaki recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water conditions To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin For safety and maximum effectiveness use cleaning and sanitizing solutions immediately after dilution a CLEANING PROCEDURE 1 Dilute 148 ml of recommended cleaner Hoshizaki Scale Away or LIME A WAY Economics Laboratory Inc with 3 8 lit of water 2 Remove the Air Filter Remove all ice from the Evaporator and the Storage Bin Note To remove cubes on the Evaporator move the Control Switch on the Control Box to the OFF position and move it back to the ICE position after 3 minutes The defrost cycle starts and the cubes will be removed from the Evaporator 3 Move the Control Switch to the OFF position Open the Door 4 Disconnect the Silicone Hose to drain the water See Fig 22 Reconnect the Silicone Hose back in its correct position after all of the water has drained 5 Pour the cleaning solution into the Water Tank Move the Control Switch to the WASH position Close the Door 61 6 After 30 minutes move the Control Switch to the OFF position 7 Same as step 4 8
22. 5A 50 10 b KM 75A 11 c COMPARTMENT 12 2 CONTROL BOARD 13 a SEQUENCE 14 b CONTROL FEATURES 17 c CONTROL BOARD LAYOUT 19 d CONTROLS AND ADJUSTMENTS 20 23 CHECKING THE CONTROL BOARD 24 3 SWITCHES 25 TECHNICAL INFORMATION 26 1 WATER CIRCUIT AND REFRIGERANT CIRCUIT 26 a KM 30A KM 35A KM 50A 26 b KM 75A e ee e ener n n ener n n n en nem T L 27 2 WIRING DIAGRAM 28 TIMING
23. Cube Guide Float Switch Water Tank 2 CONTROL BOARD A HOSHIZAKI exclusive solid state control is employed in KM 30A KM 35A KM 50A and KM 75A Crescent Cubers All models are pretested and factory adjusted CAUTION Fragile handle very carefully A control board contains integrated circuits which are susceptible to failure due to static discharge To get static free 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 Handle the board by the edges only Do not change wiring and connections Do not repair 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 the power supply to test for voltage Also never short out or modify the Terminals 13 a SEQUENCE see 3 TIMING CHART for details 1st cycle 1 Unit energized and Control Switch to ICE position 3 Thermistor reads 9 C Defrost Water supply cycle starts after 5 seconds Timer starts counting 2 After water supply cycle starts Float Switch position is checked every minute When it is in upper closed position defrost cycle starts WATER VALVE WATER VALVE HOT GAS VALVE CYCLE 6 5 IMPORTANT Water Valve opening is limited to 6 minutes To prevent
24. PEN Fig 4 2 BRAZING DANGER Refrigerant R134a itself is not explosive or poisonous However when exposed to high temperatures open flames R134a can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous Always recover the refrigerant and store it in a proper container Do not discharge the refrigerant into the atmosphere Do not use silver alloy or copper alloy containing Arsenic Do not use R134a as a mixture with pressurized air for leak testing Refrigerant leaks can be detected by charging the unit with a little refrigerant raising the pressure with nitrogen and using an electronic leak detector Note All brazing connections inside the bin are clear coated Sandpaper the brazing connections before unbrazing the components Use a good abrasive cloth to remove the coating 37 3 COMPRESSOR WARNING The Compressor Terminal Cover must be refitted in its correct position Otherwise operation under high temperature and high humidity conditions may cause electric shock fire or corrosion to shorten the service life IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until after all other repair or replacement has been made 1 Unplug the icemaker or disconnect the power source 2 Remove the Louver and Rear Cover 3 Recover the refrigerant and store it in a proper container if required by an ap
25. R PANELS To prevent corrosion wipe the exterior occasionally with a clean and soft cloth Use a damp cloth containing a neutral cleaner to wipe off all oil or dirt build up b STORAGE BIN AND SCOOP 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 c AIR FILTER The 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 Check the filter at least twice a month When it is clogged use warm water and a neutral cleaner to wash the filter d CONDENSER Check the Condenser once a year and clean if required by using a brush or vacuum cleaner More frequent cleaning may be required depending on the location of the icemaker 3 PREPARING THE ICEMAKER FOR LONG STORAGE IMPORTANT When shutting off the icemaker for an extended time drain out all water from the water lines and remove the ice from the Storage Bin The Storage Bin should be cleaned and dried Drain the icemaker using air or carbon dioxide to prevent damage to the water supply lines at sub freezing temperatures Shut off the icemaker until the proper ambient temperature is resum
26. TANT Water Valve opening is limited to 6 minutes 3 At 30 seconds before the end of defrost cycle Water Valve stops water supply and Pump Motor starts to run water on Evaporator surface At 5 minutes after thermistor temperature reaches 2 C in freeze cycle Ready to is completed and freeze cycle starts 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 after thermistor temperature reaches 2 C 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 16 b CONTROL FEATURES 1 Maximum Water Supply Period 6 minutes Inlet water valve opening in the defrost 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 2 Defrost Backup Timer The defrost backup timer shuts down the icemaker if for two cycles in a row the defrost cycle takes more than 20 minutes to complete The control board will signal this problem using 2 beeps every 3 seconds The reset button on the control board must be pressed with power on to reset the safety 3 Freeze Backup Timer The freeze backup timer shuts down the icemaker if for two cycles in a row th
27. VESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer Control BIN CONTROL SYSTEM Mechanical Level Switch with Delay Board ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe ELECTRICAL PROTENCTION Class I Appliance 5A Fuse COMPRESSOR PROTECTION Auto reset Overload Protector ICE MAKER PROTECTION Interlock by Controller Board WEIGHT Net weight 39kg Gross weight 49kg Caron ToS S OPERATING CONDITIONS VOLTAGE RANGE 198 254V AMBIENT TEMP 1 40 C WATER SUPPLY TEMP 5 35 C WATER SUPPLY PRESS 0 7 8bar 0 07 0 8MPa We reserve the right to make changes in specifications and design without prior notice b KM 50A AC SUPPLY VOLTAGE 1 PHASE 220 240V 50Hz AMPERAGE 2 2A AT 32 C WT 21 C STARTING AMPERAGE 10 7A ELECTRIC CONSUMPTION 303W AT 32 C WT 21 C POWER FACTOR 57 POWER SUPPLY CAPACITY Min 0 70KVA 2 92A Approx 52kg AT 10 C WT 10 C ICE PRODUCTION PER 24h Approx 50kg AT 21 C WT 15 C Approx 41kg AT 32 C WT 21 C Approx 0 281 AT 10 C WT 10 C WATER CONSUMPTION PER 24h Approx 0 148m AT 21 C WT 15 C Approx 0 079m AT 32 C WT 21 C SHAPE OF ICE CRESCENT CUBE FREEZE CYCLE TIME Approx 25min AT 21 C WT 15 C ICE PRODUCTION PER CYCLE Approx 0 95kg 110pcs AT 21 C WT 15 C MAX STORAGE CAPACITY Approx 23kg Bin Control Setting Approx 19kg DIMENSIONS DRAWING No 603mm W x610mm D x842mm H 003924 EXTERIOR Stainless Steel Galvanized Steel Rear INSULATION Polyuret
28. board never accepts the freeze completion signal open Float Switch within the first 5 minutes after the thermistor temperature reaches 2 C in the freeze cycle 24 3 SWITCHES Control Switch The Control Switch is located at the left front of the unit Remove the Air Filter to access the Control Switch This switch is used to place the machine into one of three modes OFF center position ICE right position and WASH left position 1 OFF In the OFF position no power is supplied to the unit However to avoid any possible risk of electrical shock disconnect the power before servicing 2 ICE This position applies power to the unit causing the automatic icemaking process to begin Refer to 2 d SEQUENCE for further details 3 WASH When the Control Switch is placed in the WASH position power is supplied to the Pump Motor and Cleaning Water Valve This allows cleaning and or sanitizing solutions see VI CLEANING AND MAINTENANCE INSTRUCTIONS to circulate throughout the water system and down the inside and outside of the Evaporator plates Front View with Louver Removed Control Switch _ 4 gt dE n za gt PACEM ll il ICE lt OFF gt WASH Fig 3 20
29. but have long defrost cycle h Hot Gas Solenoid 1 Continues to open in 1 Check for power off in Valve freeze cycle and High freeze cycle and replace Temperature Safety operates i Water Supply Line 1 Water supply off and 1 Check and get water supply cycle does recommended pressure not finish Check for water supply j Water Solenoid 1 Mesh filter or orifice 1 Clean Replace if gets clogged and water necessary supply cycle does not finish 2 Coil winding opened 3 Wiring to Water Valve 3 Check for loose connection or open replace THE CONTROL BOARD 2 Water a Float Switch 1 24 1 1 Place in continues to be E NN supplied and 2 Leads opened or 2 Check and e the icemaker defective switch will not start 30 PROBLEM POSSIBLE CAUSE REMEDY 2 Continued 3 Float does not move 3 Clean or replace freely Compressor a Control Switch will not start or 2 Check and replace operates b Overload 1 Bad contacts 1 Check for continuity and intermittently Protector replace or undercharged C 2 Coil winding opened d Start Capacitor 1 Defective e i Power Relay 1 Bad contacts 1 Check for continuity and replace 2 Coil winding opened f Compressor 1 Wiring to Compressor 1 Check for loose connection or open and replace 3 Reduce temperature and verify cause THE CONTROL BOARD Filter dust 4 Water a Water Solenoid
30. d Protector ICE MAKER PROTECTION Interlock by Controller Board WEIGHT Net weight 51kg Gross weight 64kg Caron 80500 oom E OPERATING CONDITIONS VOLTAGE RANGE 198 254V AMBIENT TEMP 1 40 C WATER SUPPLY TEMP 5 35 C WATER SUPPLY PRESS 0 7 8bar 0 07 0 8MPa We reserve the right to make changes in specifications and design without prior notice I GENERAL INFORMATION 1 CONSTRUCTION a KM 30A KM 35A KM 50A Separator Spray Tube Front Panel Louver Control Box Control Switch of 2 Hh Eua 0 Z Condenser Front View Thermistor Water Valve Pump Motor Power Supply Compressor Rear Cover Float Switch With Tank Removed Bin Control Switch b KM 75A Evaporator Water Supply Spray Tube Separator Front Panel Condenser Compressor Fan Motor Air Filter Hot Gas Valve Front View Thermistor i Drier Power Supply Drain Valve Rear View Rear Cover us iL With Tank Removed Bin Control Switch 11 c ICEMAKING COMPARTMENT Water Valve Evaporator Pump Motor SS Hy EASY 1 Dd m HH EEEE ELELE EEEE EEEE EEEE Separator XV NY AN
31. de of the Water Tank to release it from the Bracket Rail lift down the entire Water Tank and pull it toward you out of the Storage Bin Do not hit the other components 7 Refit the Water Tank in the reverse order of the removal procedure left right top rear 8 Plug in the icemaker or connect the power source 16 CUBE GUIDE 1 Remove the Water Tank see 15 WATER TANK 2 Lift off the Cube Guide out of the Water Tank 3 To refit the Cube Guide fit the Notches on both sides to the Stoppers in the Water Tank 4 The unit is provided with two or three Cube Guides quantity varies depending on model Be sure to locate the Vertical Flanges on both sides Vertical Flange Notch Cube Guide Stopper 17 SEPARATOR 1 Unplug the icemaker or disconnect the power source 2 Remove the screws at the rear and take off the Top Panel 3 Hold both sides of the Separator from the top Bend the Front Separator into a U shape and remove it from the Shaft of the Evaporator Bracket Bend the Rear Separator into an inverted U shape and lift it off the Shaft of the Evaporator Bracket 4 Refit the Separator in the reverse order of the removal procedure Check that the Separator is fit correctly on the Shaft and can swing like a pendulum 5 Plug in the icemaker or connect the power source Spray Tube Spray Guide Front Separator 18 SPRAY TUBE WATER SUPPLY PIPE
32. e freeze cycle takes longer than the time specified to complete The control board will signal this problem using 3 beeps every 3 seconds The time is factory set using dip switches 9 amp 10 The safety will be reset when the control switch is turned off and back on 4 High Temperature Safety The temperature of the suction line in the refrigeration circuit is limited by the high temperature safety This protects the unit from excessively high temperatures If the evaporator temperature rises above 53 C 4 C the thermistor operates the safety This shuts down the circuit and the icemaker automatically stops The control board will signal this problem using 1 beep every 3 seconds The reset button on the control board must be pressed with power on to reset the safety 5 Low Water Safety The control 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 control board changes to the next cycle If the float switch is in the down position electrical circuit open the control board changes to additional one minute water fill cycles until water enters the sump and the float switch closes When the float switch closes the control board changes to the next cycle The unit will not start without adequate water in the sump This serves as a low water safety to protect the water pump 6 Hi
33. ed When the icemaker is not used for two or three days it is sufficient to only move 64 the Control Switch to the OFF position unless the icemaker will be at sub freezing temperatures a Remove the water from the potable water supply line 1 Remove the Air Filter if it has not already been removed 2 Move the Control Switch on the Control Box to the OFF position 3 Unplug the icemaker or disconnect the power supply 4 Close the water supply tap and remove the Inlet Hose See Fig 31 5 Remove all ice from the Storage Bin and clean the Bin b Drain the potable Water Tank 1 Turn off the power supply at the breaker box 2 Move the Control Switch on the Control Box to the OFF position 3 Open the Door Disconnect the Silicone Hose to drain the water See Fig 21 4 Reconnect the Silicone Hose back in its correct position after all of the water has drained 5 Remove all ice from the Storage Bin and clean the Storage Bin 6 Close the Door 7 Place the Air Filter in its correct position Water Supply Tap Inlet Hose Fig 31 65
34. er all other repair or replacement has been made 1 Unplug the icemaker or disconnect the power source 2 Remove the Rear Cover 3 Recover the refrigerant and store it in a proper container if required by an applicable law see 1 b REFRIGERANT RECOVERY 4 Remove the Drier Holder if any and pull the Drier toward you for easy service 5 Remove the Drier using brazing equipment 6 Braze or solder the new Drier with the arrow on the Drier in the direction of the refrigerant flow Use nitrogen gas at a pressure of 0 2 0 3 bar when brazing tubings Braze in an Access Valve using a tee if necessary 7 Check for leaks using nitrogen gas 10 bar and soap bubbles 8 Evacuate the system and charge it with refrigerant see 1 EVACUATION AND RECHARGE 9 Refit the Rear Cover in its correct position 10 Plug in the icemaker or connect the power source Note Always use a Drier of the correct capacity and refrigerant type 39 5 HOT GAS VALVE CAUTION To ensure optimum performance use a copper tube of the same diameter and length for replacement of the hot gas circuit 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 Unplug the icemaker or disconnect the power source 2 Remove the Louver and Rear Cover 3 Recover the refrigerant and store it in a proper
35. es No adjustment is generally required If more frequent drain cycle is necessary due to water quality the Drain Counter can be readjusted as follows Dip Switch Setting ae every 2 cycles every 5 cycles every 10 cycles 5 Bin Control Switch factory adjustment mechanical Bin Control Switch is employed and not affected by ambient temperature When the Bin Switch Plate is pressed by the weight of ice for 15 seconds the unit will stop icemaking operation Then if the Bin Switch Plate is released for 90 seconds the unit will automatically start the defrost cycle to resume icemaking operation 22 YOUMS 19594 au 55918 s y jo esneo Jay y perjddns si y SUL 7 9 9 suue v YO punos 94 eq y pue dojs punos Burzzng eu uo 1esex sseJg eys punos 99 22 suue v uo SI BU ueuM SI Jewog eui sdoijs uoee punos Buizznq eu Jo yo Jo yo 295 10 AOL Ajddns 995 G JO Speeoxe Ajddns 99 JO AvGC eBeyoA Ajddns 99 G JO 10419
36. es 1 2 5 amp 6 are cleaning adjustments and the settings are flexible 2 Move the Control Switch to the ICE position and check for proper control voltage If the Power OK LED is on the control voltage is good If the LED is off check the Control Transformer circuit If no voltage is present check the power supply circuit 3 To perform a relay sequence test turn on the power switch while pressing the OUTPUT TEST button The correct lighting sequence should be 5 6 7 8 4 Some components e g the compressor will cycle during test Each LED comes on for 5 seconds LED 5 is on while LED 6 is on Following the output test sequence the icemaker will resume normal operation beginning with the initial cycle If the components cycle in a different sequence the Control Board is bad and should be replaced See V 14 d CONTROL BOARD If the components cycled in the correct sequence proceed to the next step 4 Move the Control Switch to the ICE position When the unit enters the freeze cycle allow it to run for 5 minutes after the thermistor temperature reaches 2 C in the freeze cycle and then disconnect the 3 pin Float Switch Connector gray wire The Connector is not shown but it is located in the general area of the circle in Fig 2 After the Float Switch is disconnected the defrost cycle should start If the defrost cycle does not start replace the board See V 14 d CONTROL BOARD Note The
37. gh Voltage and Low Voltage Cut outs The maximum and minimum allowable supply voltages of this icemaker are limited by the high voltage and low voltage cut outs 17 If miswiring especially on single phase 3 wire models causes excessive voltage 294Vac 5 or more on the control board the high voltage cut out shuts down the circuit in 3 seconds and the icemaker automatically stops The control board will signal this problem using 7 beeps every 3 seconds The icemaker also automatically stops in cases of insufficient voltage 184Vac 5 or less The control board will signal this problem using 6 beeps every 3 seconds When the proper supply voltage is resumed the icemaker automatically starts running again 7 LED Lights The control board includes LED indicator lights and an output test feature The POWER OK LED indicates control voltage and will remain on unless a control voltage problem occurs The POWER LED flashes continuously when the bin is full LEDs 4 through 8 energize and sequence from initial startup as listed in the table below Defrost Cycle Last 30 seconds of defrost water valve de energizes and pump motor energizes LEDs 5 6 and 7 are on Freeze Cycle 5 7 Compressor pump motor fan motor 5 6 4 hot gas valve drain valve CONTROL BOARD LAYOUT Control Board Relay LEDs 5 Connector K7 indicate which relays Transformer are energized as listed below
38. h oil or let it into the tubing as wax contained in the oil will clog the capillary tubing 5 Service Parts for R134a Some parts used for refrigerants other than R134a are similar to those for R134a But never use any parts unless they are specified for R134a because their endurance against the refrigerant have not been evaluated Also for R134a do not use any parts that have been used for other refrigerants Otherwise wax and chlorine remaining on the parts may adversely affect R134a 6 Replacement Copper Tubing R134a The copper tubes currently in use are suitable for R134a But do not use them if oily inside The residual oil in copper tubes should be as little as possible Low residual oil type copper tubes are used in the shipped units 35 7 Evacuation Vacuum Pump and Refrigerant Charge R134a Never allow the oil in the vacuum pump to flow backward The vacuum level and vacuum pump may be the same as those for the current refrigerants However the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for R134a 8 Refrigerant Leak Check Refrigerant leaks can be detected by charging the unit with a little refrigerant raising the pressure with nitrogen and using an electronic detector Do not use air or oxygen instead of nitrogen for this purpose or rise in pressure as well as in temperature may cause R134a to suddenly react with oxygen and explode Be sure to use nitroge
39. hane Foam CONNECTIONS ELECTRIC Y type Con with CONT Plug ELECTRIC European Model X type Con With Plug WATER SUPPLY Inlet G3 4 connected at rear side DRAIN Outlet 925 connected at rear side ICE MAKING SYSTEM Vertical Evaporator with water flow on both sides COMPRESSOR Hermetic 250W Model QA91K21CAW5 HOLE CONDENSER Air cooled Fin and Tube type HEAT REJECTION 920W 788kcal h AT 32 C WT 21 C EVAPORATOR Vertical type Stainless Steel and Copper REFRIGERANT CONTROL Capillary Tube REFRIGERANT CHARGE R134a 220g ICE MAKING CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer Control BIN CONTROL SYSTEM Mechanical Level Switch with Delay Board ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe ELECTRICAL PROTENCTION Class I Appliance 5A Fuse COMPRESSOR PROTECTION Auto reset Overload Protector ICE MAKER PROTECTION Interlock by Controller Board WEIGHT Net weight 46kg Gross weight 58kg Caron OPERATING CONDITIONS VOLTAGE RANGE 198 254V AMBIENT TEMP 1 40 C WATER SUPPLY TEMP 5 35 C WATER SUPPLY PRESS 0 7 8bar 0 07 0 8MPa We reserve the right to make changes in specifications and design without prior notice c KM 75A AC SUPPLY VOLTAGE 1 PHASE 220 240V 50Hz AMPERAGE 3 0A AT 32 C WT 21 C STARTING AMPERAGE 13 3A ELECTRIC CONSUMPTION 412W 2 WT 21 C POWER FACTOR 57 POWER SUPPLY CAPACITY Min 0 87KVA 3 63A Approx 72
40. he icemaker or disconnect the power source 2 Close the water supply tap 3 Remove the Top Panel and unscrew the Rear Panel 4 Disconnect the Tab Terminals 5 Pinch and lower the Hose Clamp 6 Disconnect the Rubber Hose from the Water Valve Put a towel under the Water Valve to receive water coming out 7 Turn the Inlet Nut in the arrow direction to remove it from the Water Valve Do not lose the Gasket inside 8 Remove the two mounting screws 9 Install the new valve in the reverse order of the removal procedure 10 Tighten the Inlet Nut to a torque of 7 85 Nem 596 to prevent water leaks 11 Open the water supply tap 12 Plug in the icemaker or connect the power source 13 Check for leaks 14 Refit the panels in their correct positions Tab Terminal Mounting Screw 10 DRAIN VALVE 1 Unplug the icemaker or disconnect the power source 2 Close the water supply tap 3 Drain the Water Tank see 15 WATER TANK 4 Disconnect any rigid fixed pipe for water supply and drain connections 5 Unscrew the Rear Cover Pull out the unit for easy access to the Drain Valve 6 Disconnect the Connectors or Tab Terminals of the Drain Valve lead 7 Pinch and shift the two Hose Clamps 8 Disconnect the Hoses from the Drain Valve Put a towel under the Drain Valve to receive any water coming out and prevent it from splashing out 9 Remove the two mounting screws 10 Install the new valve in the reverse o
41. kg AT 10 C WT 10 C ICE PRODUCTION PER 24h Approx 70kg AT 21 C WT 15 C Approx 55kg AT 32 C WT 21 C Approx 0 287m AT 10 C WT 10 C WATER CONSUMPTION PER 24h Approx 0 118m AT 21 C WT 15 C Approx 0 071m AT 32 C WT 21 C SHAPE OF ICE CRESCENT CUBE FREEZE CYCLE TIME Approx 24min AT 21 C WT 15 C ICE PRODUCTION PER CYCLE Approx 1 25kg 130pcs AT 21 C WT 15 C MAX STORAGE CAPACITY Approx 40kg Bin Control Setting Approx 34kg DIMENSIONS DRAWING No 603mm W x712mm D x842mm H 003926 EXTERIOR Stainless Steel Galvanized Steel Rear INSULATION Polyurethane Foam CONNECTIONS ELECTRIC Y type Con with CONT Plug ELECTRIC European Model X type Con With Plug WATER SUPPLY Inlet G3 4 connected at rear side DRAIN Outlet 925 connected at rear side ICE MAKING SYSTEM Vertical Evaporator with water flow on both sides COMPRESSOR Hermetic Model QA125K26CAW5 HOLE CONDENSER Air cooled Fin and Tube type HEAT REJECTION 1050W 904kcal h AT 32 C WT 21 C EVAPORATOR Vertical type Stainless Steel and Copper REFRIGERANT CONTROL Thermostatic Expansion Valve REFRIGERANT CHARGE R134a 240g ICE MAKING CONTROL SYSTEM Float Switch HARVESTING CONTROL SYSTEM Hot Gas and Water Thermistor and Timer Control BIN CONTROL SYSTEM Mechanical Level Switch with Delay Board ICE MAKING WATER CONTROL Timer Controlled Overflow Pipe ELECTRICAL PROTENCTION Class I Appliance 5A Fuse COMPRESSOR PROTECTION Auto reset Overloa
42. lation and secure them with the Ties Keep the Thermistor inside the Thermistor Holder After the Thermistor Holder is fitted do not pull the Thermistor lead to move the Thermistor 9 Refit the removed parts in the reverse order of the removal procedure 10 Plug in the icemaker or connect the power source Thermistor Lead Tie After Thermistor Holder is fitted do not pull Thermistor lead Insulation Thermistor Holder Fit right on top of pipe Fill up to slightly above top of recess Fill in shaded area Do not let in air and make a hollow in recess Fig 20 53 14 CONTROL BOX 1 Unplug the icemaker or disconnect the power source 2 Remove the Louver 3 Tilt the Tabs inward at the same time on both sides of the Control Box and pull the Control Box toward you Tilting only one Tab will not work 4 To refit the Control Box push it in horizontally Control Box Control Box ower Relay Fuse Fuse Holder Transformer Capacitor Power Switch KM 50 75 only Note After replacing the components inside the Control Box connect and tie the wires properly in their correct position Especially make sure that the Harness does not press the Push Buttons on the Control Board a POWER SWITCH 1 Disconnect the Tab Terminals and remove the Nut securing the Power Switch 2 Install the new Switch in the reverse order of the removal procedure 3 To prevent miswiring check the terminal
43. m pipes and keep brazing equipment away from other parts to prevent burning Remove band from Bulb with a screwdriver Fig 6 43 7 FAN MOTOR 1 Unplug the icemaker or disconnect the power source 2 Remove the Louver 3 Disconnect the Connector of the Fan Motor lead 4 Remove the two screws securing the Fan Motor Bracket and pull out the Fan Motor in the arrow direction To prevent deformation do not hit the Fan on the Condenser or other parts 5 Install the new Fan Motor in the reverse order of the removal procedure 6 Refit the Louver in its correct position 7 Plug in the icemaker or connect the power source Fan Motor Fan Motor Bracket Screw 44 8 PUMP MOTOR 1 Unplug the icemaker or disconnect the power source 2 Remove the Top Panel and unscrew the Rear Panel 3 Disconnect the Connector of the Pump Motor lead 4 Remove the Water Tank see 15 WATER TANK 5 Remove the ties connecting the Pump Motor discharge outlet and pull off the gt Fig 8 6 Remove the screw securing the Pump Motor Shift the Case to the center to release T Lift off it from the Stopper and lift off the Pump Motor Stopper Fig 9 7 Install the new motor in the reverse order of the removal procedure 8 Plug in the icemaker or connect the power source and check for leaks 9 Refit the panels in their correct positions 45 9 WATER VALVE 1 Unplug t
44. n to prevent explosion b REFRIGERANT RECOVERY No refrigerant Access Valve is provided in the unit Install a proper Access Valve on the low side line ex Compressor Process Pipe Recover the refrigerant from the Access Valve and store it in a proper container Do not discharge the refrigerant into the atmosphere c EVACUATION AND RECHARGE 1 Attach Charging Hoses a Service Manifold and a Vacuum Pump to the system 2 Turn on the Vacuum Pump 3 Allow the Vacuum Pump to pull down to a 760 mmHg vacuum Evacuating period depends on the pump capacity 4 Close the Low side Valve on the Service Manifold 5 Disconnect the Vacuum Pump and attach a Refrigerant Charging Cylinder Remember to loosen the connection and purge the air from the Hose See the Nameplate for the required refrigerant charge 6 Open the Low side Valve Do not invert the Charging Cylinder A liquid charge will damage the Compressor 7 Turn on the icemaker when charging speed gets slow Turn off the icemaker when the Low side Gauge shows approximately 0 kg cm Do not run the icemaker at vacuum pressures Close the Low side Valve when the Charging Cylinder gets empty 36 8 Repeat steps 4 through 7 if necessary until the required amount of refrigerant has entered the system 9 Close the Refrigerant Access Valve and disconnect the Hoses Service Manifold etc 10 Cap the Access Valve to prevent possible leak Depressed Cap Access Valve O
45. nd replace time is too defective switch long 2 Float does not move 2 Clean or replace freely b Water Solenoid 1 Diaphragm does not 1 Check for water leaks Valve close with icemaker off Replace if necessary THE CONTROL BOARD 2 All ice formed does not fall recommended pressure into bin in c Water Solenoid 1 B AN mesh filter or 1 eer defrost cycle Valve B AN 2 does not 2 oc NN for water leaks with icemaker off if necessary S Then tem perature attachment THERMISTOR Control Board 1 Defrost Timer is set too 1 Adjust longer referring to short 2 e CONTROLS AND ADJUSTMENTS 3 Defrost Timer 32 PROBLEM POSSIBLE CAUSE REMEDY 2 Continued 2 Defective 2 See Il 2 f CHECKING THE CONTROL BOARD 3 Others a Spray Tubes 1 Clogged 2 Out of position 2 Place in position Da ss stem recharge ae 75 only loose attachment e Hot Gas Solenoid Valve 3 Wiring to Hot Gas 3 Check for loose Valve connection or open and replace f Water Supply Line 1 Too small requires 9 5 1 Increase water supply line mm OD line dedicated size per machine has larger flow rate 3 LOW ICE PRODUCTION 1 Freeze cycle a See chart 1 3 and check dirty Air Filter or Condenser ambient or water time is long temperature water pressure and refrigerant charge b See chart 2 1 and check Float Switch Water Solenoid Valve and Control Board 2 Defr
46. numbers and lead wire colors with the Wiring Label b FUSE 1 Use a phillips head screwdriver to remove the Fuse Holder Cap and take out the Fuse 2 Install the new Fuse in the reverse order of the removal procedure c FUSE HOLDER 1 Disconnect the Tab Terminal and remove the Nut securing the Fuse Holder 2 Install the new Fuse Holder in the reverse order of the removal procedure d CONTROL BOARD 1 Disconnect all the Connectors 2 Pull the Tab to release the Control Board 3 Lift off the Control Board 4 To refit the Control Board fit its four corner holes on the positioning lugs inside the Control Box and secure the Control Board with the Tab 5 When reconnecting the Connectors do not push them too hard The Control Board may be damaged e POWER RELAY 1 Disconnect the Tab Terminals remove the mounting screw and lift off the Power 55 Relay from the fit at the bottom 2 Install the new Relay in the reverse order of the removal procedure 3 To prevent miswiring check the terminal numbers and lead wire colors with the Wiring Label COMPRESSOR CAPACITOR KM 50A KM 75A ONLY 1 Disconnect the Tab Terminals and cut the Tie 2 Install the new Capacitor in the reverse order of the removal procedure Use a cable tie to secure the Capacitor tightly g CONTROL BOARD TRANSFORMER 1 Disconnect the Connectors and Closed End Connectors connecting the Control Board The Tie securing the harness
47. ost cycle a See chart 2 2 and check Control Board Thermistor Evaporator ambient time is long and or water temperature water supply line and Water Solenoid Valve 4 ABNORMAL ICE PROBLEM POSSIBLE CAUSE REMEDY 1 Small cubes a Cube Guide 1 Out of position 1 Check that Cube Guide is Water Tank Circulated water falls properly installed on into bin Water Tank and tank is fixed securely with snaps b See chart 1 5 and check water supply line Water Solenoid Valve water system Pump Motor and Control Board 2 Cloudy or a See chart 2 1 and 3 and check Float Switch Water Solenoid Valve irregular cubes Control Board Spray Tubes water system refrigerant charge and Expansion Valve b Spray Guide c Water Quality 1 High hardness or 1 Install a water filter or contains impurities softener 33 5 OTHERS PROBLEM POSSIBLE CAUSE REMEDY 1 Icemaker will a Bin Control Switch 1 Completely 1 Place in position not stop when disconnected and bin is filled with dropped inside bin ice 2 Detector broken 3 Detector out of position 3 Place in position replace position 6 Magnet disconnected 6 Place in position from Detector b Control Board 1 Defective 1 See Il 2 f CHECKING THE CONTROL BOARD 2 Abnormal noise b Fan Motor move freely cylinder valve broken 2 Mounting pad out of 2 Reinstall position or loose hold down bolt other surfaces 3 Ice in S
48. owing Cleaning Procedure 1 Dilute approximately 15 ml or 1 tbs of a 5 25 sodium hypochlorite solution chlorine bleach with 3 8 lit of warm water Using a chlorine test strip or other method confirm that you have a concentration of about 200 ppm 2 Soak the removed parts from step 16 above in a clean container containing the sanitizing solution After allowing the parts to soak for 10 minutes wash them with the solution Also wash the bin liner Bracket L R with the solution 3 Discard the sanitizing solution and rinse the parts thoroughly with water 4 Replace the removed parts in their correct positions in the reverse order of which they were removed 5 Same as step 1 6 Pour the sanitizing solution into the Water Tank and allow the sanitizer to sit for 10 minutes 7 Move the Control Switch to the WASH position Close the Door 8 After 15 minutes move the Control Switch to the OFF position Open the Door 9 Disconnect the Silicone Hose to drain the water Reconnect the Silicone Hose back in its correct position after all of the water has drained 10 Repeat steps 5 through 9 one time Repeat steps 8 through 11 in the Cleaning Procedure three times to rinse thoroughly 11 Flush the Storage Bin with water 12 Move the Control Switch to the ICE position and start the automatic icemaking process 13 Close the Door Replace the Air Filter in its correct position 63 2 MAINTENANCE a EXTERIO
49. plicable law see 1 b REFRIGERANT RECOVERY 4 Remove the Terminal Cover on the Compressor and disconnect Solderless Terminals 5 Disconnect 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 8 Attach the Rubber Grommets of the previous Compressor 9 Clean the Suction and Discharge Pipes with an abrasive cloth paper 10 Place the Compressor in position and secure it using the Bolts and Washers 11 Remove Plugs from the Compressor Suction and Discharge Pipes 12 Braze or solder the Access Suction and Discharge lines Do not change this order with nitrogen gas flowing at a pressure of 0 2 0 3 bar 13 Install the new Drier see 4 DRIER 14 Check for leaks using nitrogen gas 10 bar and soap bubbles 15 Evacuate the system and charge it with refrigerant see 1 c EVACUATION AND RECHARGE 38 16 Connect the Solderless Terminals and replace the Terminal Cover in its correct position 17 Refit the Louver and Rear Cover in their correct positions 18 Plug in the icemaker or connect the power source Note Hoshizaki recommends that Compressor starting electrics are always replaced at the same time as the Compressor 4 DRIER IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened Do not replace the Drier until aft
50. rder of the removal procedure 11 Reconnect the water supply and drain connections if disconnected in step 4 12 Open the water supply tap 13 Plug in the icemaker or connect the power source 14 Check for leaks 15 Refit the panels in their correct positions Mounting Screw Hose Clamp Hose Clamp Fig 11 Pinch and shift to left Pinch and lower 47 11 FLOAT SWITCH a KM 30A KM 35A KM 50A 1 Unplug the icemaker or disconnect the power source 2 Remove the Top Panel and unscrew the Rear Panel 3 Disconnect the Connector of the Float Switch lead and remove the lead wire from the Grommet through the slit 4 Remove the Water Tank see 15 WATER TANK 5 Remove the screw securing the Float Switch 6 Install the new Float Switch in the reverse order of the removal procedure 7 Refit the panels in their correct positions 8 Plug in the icemaker or connect the power source Float Switch Attach to three arrowed surfaces when fixing with screw Fig 12 48 b KM 75A 1 Unplug the icemaker or disconnect the power source 2 Remove the Top Panel and unscrew the Rear Panel 3 Disconnect the Connector of the Float Switch lead gray 4 The Float Switch is located behind the Pump Motor Pinch the arrowed part 1 and pull it diagonally forward 2 to unhook the Float Switch Pump Motor Hook B Float Switch Fig 13 5 Remove the screw securing the Float Switch to the Bracket
51. slushing Pump Motor stops seo see Ill 3 TIMING CHART PUMP MOTOR 4 At 30 seconds before lt FANMOTOR FAN MOTOR Water Valve stops water supply and Pump Motor starts to run water on Evaporator surface At 5 minutes after thermistor temperature 5 Defrost Timer stops counting Defrost cycle reaches 2 C in freeze cycle Ready to is completed and freeze cycle starts 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 after thermistor temperature reaches 2 C 2 Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting 14 2nd cycle and after IMPORTANT Freeze cycle time is limited to the time set by Freeze Backup Timer on Control Board see d CONTROLS AND ADJUSTMENTS even if Float Switch does not open 1 Float Switch opens and signals to complete 2 Thermistor reads 9 C Defrost freeze cycle Timer starts counting WATER VALVE 4 2 DEFROST CYCLE To prevent slushing Pump Motor stops IMPORTANT Water Valve opening is limited to 6 minutes see Ill 3 TIMING CHART 3 At 30 seconds before the end of defrost cycle Water Valve stops water supply and Pump Motor starts to run water on
52. torage a Bin Drain 1 Plugged 1 Clean melts 34 V REMOVAL AND REPLACEMENT 1 SERVICE FOR REFRIGERANT LINES a SERVICE INFORMATION 1 Allowable Compressor Opening Time and Prevention of Lubricant Mixture R134a The compressor must not be opened more than 30 minutes in replacement or service Do not mix lubricants of different compressors even if both are charged with the same refrigerant except when they use the same lubricant 2 Treatment for Refrigerant Leak R134a If a refrigerant leak occurs in the low side of an ice maker air may be drawn in Even if the low side pressure is higher than the atmospheric pressure in normal operation a continuous refrigerant leak will eventually lower the low side pressure below the atmospheric pressure and will cause air suction Air contains a large amount of moisture and ester oil easily absorbs a lot of moisture If an ice maker charged with R134a has possibly drawn in air the drier must be replaced Be sure to use a drier designed for R134a 3 Handling of Handy Flux R134a Repair of the refrigerant circuit requires brazing It is no problem to use the same handy flux that has been used for the current refrigerants However its entrance into the refrigerant circuit should be avoided as much as possible 4 Oil for Processing of Copper Tubing R134a When processing the copper tubing for service wipe off oil if any used by using alcohol or the like Do not use too muc
53. witch Nos 3 and 4 Used for adjustment of the Drain Timer and the minimum defrost time Once every ten freeze cycles the Drain Valve opens to drain the Water Tank for the time determined by the Drain Timer These switches also determine the time to delay completion of a defrost cycle i e the minimum defrost time Do not change this setting or the unit will not operate properly or produce high quality ice Switch Nos 5 and 6 Used for adjustment of the Drain Counter The Drain Valve opens to drain the Water Tank at the frequency determined by the Drain Counter Once every ten freeze cycles the Drain Valve drains the Water Tank to clean inside the tank and prevent cloudy ice production by concentrated icemaking water This function ensures proper operation even in hard water conditions The frequency of this drain cycle can be changed to every cycle every two cycles or every five cycles Switch Nos 7 and 8 Used for adjustment of the Water Saver The Water Saver closes the Water Valve to save water when the Pump Motor starts to supply water to the Evaporator 30 seconds before the end of defrost cycle Do not change this setting 20 Switch Nos 9 and 10 Used for adjustment of the Freeze Backup Timer The freeze cycle backup time is set to 120 minutes Do not change this setting The Control Board is located inside the Control Box Drain Frequency Control 5 amp 6 Drain Timer 3 amp 4 Defrost Timer 1 amp 2 Fig 1
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