Service Manual
Contents
1. 3401501301913 HMH H0 dH dU 34 4 Ol 44 440 34 1 30 HH HAT AH 440 440 440 440 440 440 380 4 Hv QN 7 H 8 i QN 7 1 1 135 11 7195 1005 SN HOLING Hk l s J el RIP der k k LA a 4 1 h d 3m p EU i H 4 ug 31 gt Si 5 By y e a 4 A Te Le SH m X TE qr 31 H 13N 4 4 4 d 5 1093104 1 ul Hill 1074 gros A mu NONE D I 22. 15 Default Dip Switch Settings arsi 15 b Harvest Timer dip switch 1 amp 2 15 c Pump Out Timer dip switch amp 4 ie nomen nhat n nh 16 d Pump Out Frequency Control dip switch 5 amp 6 16 Freeze Timer dip switch 9 amp 10 17 4 Control Board Check Procecdure 17 5 Control Board Replacement iiie eere ph haad niit SR EFE EXER EE FkN EN Ra anna 17 D Harvest Control Thermistor EE 18 ggg H 18 gie ean MENT 18 DALTON SHUI EE 18 SEENEN 19 H RE 19 1 EEN 19 E EE 19 Technical Information 20 Water Circuit Refrigeration E 20 1 d IERT EE 20 E 21 B Winng GE 22 1 KML 451MAH air cooled KML 451MWH water cooled 22 C Performance elie ascot 23 1 KML 451MAH RE e E 23 2 KML 451MWH water cooled EE 24 IV Service Ee e 25 A 10 Minute Diagnostic Procedure 25 B Diagnostic CMAN NS 26 lce 26 SES IS Frozen enee EE ies 30 SEES ICS RrodUCUON 31 E E 31 31 V Removal and Replacem
3. lt s 4 lt S 3 4 dnyeis jeu D UI lt 1005 095 4 nuu gc O UI 20451 ejo 9 1 Bumes oun e OZ e 9 2A2 1no duing SOINUIW ezeeJj e 9 JOYEM 19 UI UJnUJIXe N e L 2 D 2 4 54915 2 1ueuoduio pue eyg eouenbes HMI LGb 1INX HYN LGb 1A 10 Control Board A HOSHIZAKI exclusive solid state control is employed in KML 451MAH and KML 451MWH Modular Crescent Cubers All models are pretested and factory adjusted CAUTION 1 Fragile handle very carefully Acontrol board contains integrated circuits which are susceptible to failure due to static discharge It is especially important to touch the metal part of the unit when handling or replacing the board Do not touch the electronic devices on the board or the back of the board to prevent damage to the board Do not change wiring and connections Do not misconnect K4 and K5 because the same connector is used for the thermistor and float switch K4 is not connected Always replace the whole board as
4. 44 B Ela Ee 45 C Preparing the Icemaker for Long Storage SCNKSENSENEENEREEEASSREEEEEEEENENEEEREENEEENESENENER e 45 Specifications Icemaker 1 KML 451MAH 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 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 115 60 1 10 3A 5 Min Freeze AT 104 F WT 80 F 20A WATER TEMP 50 70 90 403 183 387 176 355 161 Crescent Cube 7 0 Ibs 3 2 kg 360 pcs N A 90 70 70 50 970 6 7 890 5 3 64 18 3 115 28 5 30 x 27 3 8 x 22 762 x 695 x 560 mm Stainless Steel Galvanized Steel Rear Net 154 Ibs 70 kg Shipping 185 16 84 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT Float Switch Hot G
5. pinbii ATT 526 10U AOH siu pue y paijddns si Jo JO ees HSVM PU 31V 1110HIO SUOHISOd 9914 seu uos eu 1 aui pue YOUMS 0 JOMOd uoiws 041009 au uonisod 39IAH3S 24 ur ueuM 32IAH3S 941 U S 041u02 eui sjueuoduio YOUMS 1e0JI S 4 peurejuoo jJJes SI JOJOW Josseidwoo dwog E SE E EE pue uado 1 4 JI senunuoo pezibieus 7990 5 4 A11 01 G Z pezi amp ueue ep AM Sues senunuoo AM uoee 08S 02 01 104 AG 40149 0 pezibieue ep ADH 5591 10 Ox 6 pezibjeue uedo S 4 9 Nd sezifjeue Doum uonejedo senunuoo 2 6 4 89 7 ASH dwog AM puooes HS 295 2 10 sdois Wd 9 o o 9729914 senunuoo dwog duet 101siuu8u
6. Spray Tubes Drain Valve Junction Box Condenser Control Box N N ge AN Sa SSS gt 2 PEE o o lt gt gt 222 WSF TEN ON NN Water Pump Drier Float Switch Expansion Valve Hot Gas Valve Control Compressor Switches Bin Control Thermostat 2 KML 451MWH water cooled Water Supply Water Spray Tubes Regulator Drain Valve Junction Box Condenser Control Box Wash Valve Inlet Water Valve Water Pump Drier Float Switch Expansion Valve Hot Gas Valve Control Compressor Switches Bin Control Thermostat Sequence of Operation The steps in the sequence are as outlined below When power is supplied 5 second delay occurs at startup Note that the order of the LEDs from the outer edge of the board is 1 4 3 2 One Minute Fill Cycle LED 4 is on WV opens and the fill period begins After 1 minute the board checks for a closed F S If F S is closed the harvest cycle begins If not WV will remain energized through additional 1 minute cycles until water enters the sump and F S closes This serves as a low water safety to protect the water pump Initial Harvest Cycle LEDs 1 4 and 2 are on WV remains open Comp and FMR energize HGV opens and harvest begins As the evaporator warms the thermis
7. 2 minutes 11 Turn off the power supply 44 Remove the front panel Repeat steps 18 through 31 in 1 Cleaning Procedure two times to rinse thoroughly 12 13 14 Move the control switch to the ICE position 15 Replace the front panel in its correct position 16 Clean the storage bin with water 17 Turn on the power supply and start the automatic icemaking process B Maintenance 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 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 rinsing thoroughly Clean the bin liner by using a neutral cleaner Rinse thoroughly after cleaning 3 Air Filter air cooled models only A plastic mesh air filter removes dirt or dust from the air and keeps the condenser from getting clogged As the filter gets clogged the icemaker s performance will be reduced Check the filter at least twice a month When clogged use warm water and a neutral cleaner to wash the filter 4 Condenser air cooled and remote air cooled models only Check the condenser once a year and clean if required by using a brush or vacuum cleaner More frequent cleaning may be req
8. ACCESSORIES SUPPLIED REQUIRED OPERATING CONDITIONS 115 60 1 8 9 A 5 Min Freeze 104 F WT 80 F 20A WATER TEMP F CF 50 70 90 404 183 402 182 384 174 402 183 399 181 373 169 402 182 397 180 374 169 393 178 392 178 352 160 Crescent Cube 6 8 Ibs 3 1 kg 360 pcs N A 90 70 F 70 50 F 880 5 3 860 5 1 78 19 7 125 31 0 548 138 319 79 30 x 27 3 8 x 22 762 x 695 x 560 mm Stainless Steel Galvanized Steel Rear Net 154 Ibs 70 kg Shipping 185 108 84 kg Permanent Connection Inlet 1 2 FPT Condenser Inlet 1 2 FPT Outlet 3 4 FPT Condenser Outlet 3 8 FPT Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe Water Regulator Thermostat Hermetic Model RS43C2E CAA 219 Water cooled Tube in tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R 404A 116 2 3 520g High 427PSIG Low 230PSIG 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 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 General Information A Construction 1 KML 451MAH air cooled Condenser Water Supply Inlet Fan Motor
9. This manual should be made available to the technician prior to service or maintenance CONTENTS Nek GE Ee 1 451 air cooled iiiieiieeuie iier en rant nana arn nnn n BRA Ra 2 KML 451MWH ll General Pic EE 1 451 2 KML 451MWH Sequence of Operation EN 1 One Minute Fill Cycle gt 2 Initial Harvest Cycle c 3 Freeze e 4 Pump Out Cycle 5 Normal Harvest Cycle eec E ON Board EE 11 1 Control Board BE EE 12 EUN IPIE ONU cT 13 a Maximum Water Supply Period 6 minutes 13 b Harvest Backup Timer and Freeze 13 High Temperature 5 1 13 d Low Water Safety Jue estas tetendit intimam eng Ea exu tens conu reua inten mex ncn i 1 High Voltage and Low Voltage 13 f LED Lights and Audible Alarm Gatetes 14 3 Controls and Adjustments
10. hot gas valve is open water valve still open Average harvest cycle at factory setting is 2 to 3 minutes How long does initial harvest last 1 5 minutes after initial harvest begins touch the compressor discharge line Is it hot If not check refrigerant pressures and compressor operation If it is hot touch the inlet line to the evaporator Is it hot If it is hot and the freeze cycle is not starting check the harvest timer adjustment the thermistor for open circuit the discharge line temperature compressor efficiency and if the hot gas valve is fully open 5 Freeze Cycle Compressor remains energized pump motor line valve if applicable and fan motor energize The inlet water valve and hot gas valve de energize The unit is held in freeze by a 5 minute short cycle protection timer After 5 minutes the freeze cycle operation is transferred to the float switch for freeze termination During the first 5 minutes of freeze confirm that the evaporator temperature drops After 7 minutes in freeze remove the black float switch lead from the K5 connector The unit should immediately switch to the pump out cycle Diagnosis If the evaporator is not cold check to see if the hot gas valve is still open or if the expansion valve is not opening properly if the water valve is continuing to fill the reservoir if there are improper unit pressures an inoperative compressor or an inoperative headmaster C P R remote condenser unit only If th
11. 3 Check that the condenser drain temperature is stable Adjustment Screw CW Higher CCW Lower Top View Fig 1 H Removal and Replacement of Headmaster Condensing Pressure Regulator C P R Remote Air 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 2 3 4 5 6 Turn off the power supply Remove the panels from the remote condenser unit Recover the refrigerant and store it in an approved container Before heating break off the stub on the dome to release the dome charge Disconnect the headmaster a Tae a ee Place the new headmaster in position 39 7 Braze the fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG CAUTION Always protect the headmaster body by using a damp cloth to prevent it from overheating Do not braze with the headmaster body exceeding 250 F 121 C 8 9 0 1 Remove the drier in the icemaker then place the new drier in position Braze the fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG Check for leaks using nitrogen gas 140 PSIG and soap bubbles 1 11 Evacuate the system and charge it with refrigerant For the required refrigerant charge see the charge label in the machine compartment of the icemaker 12 Replace the panels in their cor
12. Switch Settings 55 Dip Switch Do Not Adjust Auxiliary Code 2314 5 EE Ojo Ojo 919 919 T T T T o T T T E TI SESESESESL 2222 2221 EE 7 EIE T T T T T T T T KML 250MWH 1 and Later KML 351MAH 1 and Later KML 351MWH KML 451MAH F T T TI A E 7 KML 451MWH F KML 631MAH F KML 631MWH 0 and Later OFF KML 631MRH 0 and Later OFF OF EE mim 7 a 54 Dip Switch 55 Dip Switch Do Not Adjust mme Refill Counter through 5 IR Ve Float Switch Selector 1 B Wiring Diagram 1 KML 451MAH and KML 451MWH B 1 and Later 131 3716 L 4018 22 82 22222 _ z V8 po 5 U91IAS
13. and hot gas valve 4 Abnormal Ice Possible Cause 1 Small cubes a Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin b See chart 1 5 and check water supply line inlet water valve water system pump motor and control board 2 Cloudy or irregular a See chart 2 1 and 2 3 and check float switch inlet water valve control cubes board spray tubes water system refrigerant charge and expansion valve b Spray Guide c Water Quality 1 High hardness or 1 Install a water softener or contains impurities filter 5 Other Possible Cause 1 cemaker will not stop Bin Control Thermostat 1 Set too cold 1 Adjust warmer when bin is filled with ice 2 Defective 2 Replace 2 Abnormal noise a Pump Motor 1 Bearings worn out 1 Replace b Fan Motor 1 Bearings worn out 1 Replace 2 Fan blade deformed 2 Replace fan blade 3 Fan blade does not 3 Replace move freely c Compressor 1 Bearings worn out or 1 Replace cylinder valve broken 31 Possible Cause 2 Abnormal noise c Compressor 2 Mounting pad out of 2 Reinstall continued continued position d Refrigerant Lines 1 Rub or touch other 1 Replace lines or surfaces 3 Ice in storage bin a Drain Line s 1 Plugged often melts b and Bin 1 Drains not run 1 Separate the drain lines separately Ice Cube Guide 1 Out of position 1 Place in pos
14. and process pipes Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG Check for leaks using nitrogen gas 140 PSIG and soap bubbles 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 rating label inside the icemaker 15 Connect the terminals and replace the terminal cover in its correct position 16 Replace the panels in their correct positions 17 Turn on the power supply 35 Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigeration 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 3 Recover the refrigerant and store it in an approved container 4 Remove the insulation and the expansion valve bulb on the suction line 5 Remove the expansion valve cover and disconnect the expansion valve Place the new expansion valve in position 6 Remove the drier then place the new drier in position 7 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG WARNING Always protect the valve body by using a damp cloth to prevent the valve fro
15. board setting pump out occurs every cycle or every 2nd 5th or 10th cycle dip switch 5 amp 6 Normal Harvest Cycle LEDs 1 4 and 2 are on Comp and FMR continue to run HGV remains open and WV opens As the evaporator warms the thermistor reaches 48 F 9 C The control board then receives the thermistor s 3 9 signal and starts the harvest timer The water valve is open during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter When the harvest timer completes its count down the harvest cycle is complete and the next freeze cycle starts The unit continues to cycle through 3 4 and 5 sequence until the bin control senses ice and shuts the unit down Legend Comp compressor DV Drain Valve FWR remote fan motor FMS self contained fan motor F S float switch HGV hot gas valve LLV Liquid Line Valve PM pump motor SR Service Relay WV inlet water valve 9 BU JO seoeuins pue eui Jezniues pue pesn siu aaea ysem pue y si eu JO eoeuns y euin JO spoued JO pesn eq ueo siu AjUO y paijddns si Jamog 1 19JUI AM 4 Jojow dwnd Nd
16. is required T1 Time to drain the water tank T2 Harvest timer at pump out Pump out always occurs on the 2nd harvest after startup Then depending on the pump out frequency control setting dip switch 5 amp 6 pump out occurs every cycle or every 2nd 5th or 10th cycle d Pump Out Frequency Control dip switch 5 amp 6 The pump motor drains the water tank at the frequency set by the pump out frequency control The pump out frequency control is factory adjusted to drain the water tank every 10 cycles and no adjustment is required However where water quality is bad and the icemaker needs a pump drain more often the pump out frequency can be adjusted as shown in the table below Dip Switch Setting Frequency Freeze Timer dip switch 9 amp 10 CAUTION Adjust to proper specification or the unit may not operate correctly The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze up issues Upon termination of freeze timer machine initiates the harvest cycle After 2 consecutive timer terminations machine will shut down possibly indicating a problem The freeze timer is factory adjusted and no adjustment is required Tine Lor SS 50 ON ON 60 4 Control Board Check Procedure Before replacing a control board that does not show a visible defect and that you suspect is bad always conduct the following check procedure This procedure will h
17. low side access valves IMPORTANT The vacuum level and vacuum pump may be the same as those for current refrigerants However the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils 2 Turn on the vacuum pump 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 depends on pump capacity 4 Close the low side valve and high side valve on the service manifold 5 Disconnect the vacuum pump and attach a refrigerant service cylinder to the high side line Remember to loosen the connection and purge the air from the hose For air cooled and water cooled models see the nameplate for the required refrigerant charge For remote air cooled models see the rating label inside the icemaker Hoshizaki recommends only virgin refrigerant 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 and place it on scales Open the high side valve on the service manifold 7 Allow the system to charge with liquid until the proper charge weight is met 8 If necessary add any remaining charge to the system through the low side 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 ac
18. using compressed air or carbon dioxide until water stops coming out 2 Remove the water from the potable water supply line 1 Turn off the power supply and remove the front panel 2 Move the control switch on the control box to the OFF position 3 Wait 3 minutes 4 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 ICE position 8 Replace the front panel and turn on the power supply 9 Blow the potable water line out using compressed air or carbon dioxide 3 Drain the Potable Water Tank 1 Turn off the power supply 2 Remove the front panel 3 Move the control switch to SERVICE and move the service switch to the DRAIN position 4 Replace the front panel and turn on the power supply for 2 minutes 5 Turn off the power supply 6 Close water supply line drain valve s 46 2013 ADDENDUM Switch Settings 1 54 Dip Switch Settings CEN Auxiliary Code KML 250MAH B 1 and Later KML 250MWH B 1 and Later S4 Dip Switch o 2 T ri GEIER nmm 919 81 gg 212 KML 351MAH 1 and Later OFF KML 351MWH KML 451MWH KML 631MAH KML 631MWH OFF 2 S5 Dip
19. water valve 14 3 Controls and Adjustments a Default Dip Switch Settings The dip switch is factory adjusted to the following positions DEU Freeze Timer 9 amp 10 Normally in the OFF position Pump Out Frequency Control 5 amp 6 Pump Out Timer 3 amp 4 Harvest Timer 1 amp 2 b Harvest Timer dip switch 1 amp 2 The harvest timer starts counting when the thermistor reads 48 F 9 C at the evaporator outlet No adjustment is required under normal use as the harvest timer is adjusted to the suitable position However a setting longer than the factory setting may be advised in cases where the flush provided at harvest needs to be prolonged for extra cleaning Before changing this setting call the HOSHIZAKI Technical Support Department at 1 800 233 1940 for recommendations Keep in mind that setting the harvest timer to a longer setting will decrease 24 hour production Time seconds Torr ore e ON OFF 90 15 Pump Out Timer dip switch 3 amp 4 When a freeze cycle is completed the pump motor stops and the icemaker resumes operation in 2 seconds Then during cycles when a pump out is called for the pump motor drains the water tank for the time determined by the pump out timer The pump out timer also acts in place of the harvest timer during cycles with a pump out The pump out timer is factory adjusted and no adjustment
20. where the refrigeration tubings pass through the molded chassis 5 Disconnect the evaporator tubing 6 Remove the pop rivets securing the evaporator then lift out the evaporator 7 Install the new evaporator 37 8 9 0 1 Remove the drier then place the new drier in position Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 10 Check for leaks using nitrogen gas 140 PSIG and soap bubbles 1 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 rating label inside the icemaker 12 Replace the removed parts in the reverse order of which they were removed 13 Replace the top insulation and the panels in their correct positions 14 Turn on the power supply F Removal and Replacement of Water Regulating Valve Water Cooled Model Only IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made 1 Turn off the power supply Close the water supply line shut off valve C2 Remove the panels Recover the refrigerant and store it in an approved container Wu Disconnect the capillary tube at condenser outlet Disconnect the flare connections of the valve Remove the screws and the valve from the br
21. Capacitor or Run 1 Defective 1 Replace Capacitor Internal Overload 1 Loose terminal 1 Tighten or replace Protector Open check 1 through 3 to the right 2 Voltage 2 Check and correct and d through f below 3 Dirty condenser 3 Clean d Starter 1 Bad contacts 1 Check and replace 2 Coil winding opened 2 Replace e Compressor 1 Wiring to compressor 1 Check for loose connection or open and replace 2 Defective 2 Replace 3 Protector tripped 3 Reduce temperature f Control Board 1 No power to contactor 1 See 1 4 Control Board Check Procedure 4 Water continues to Inlet Water Valve 1 Diaphragm does 1 Check for water leaks with be supplied in freeze close icemaker off cycle b Control Board 1 Defective 1 See II C 4 Control Board Check Procedure 5 No water comes from a Water Supply Line 1 Water pressure too 1 Check and get spray tubes Water low and water level in recommended pressure pump will not start or water tank too low freeze cycle time b Inlet Water Valve 1 Dirty mesh filter or 1 Clean too short orifice and water level in water tank too low c Water System 1 Water leaks 1 Check connections for water leaks and replace 2 Clogged d Pump Motor 1 Motor winding opened 1 Replace 2 Bearing worn out 2 Replace 28 5 water comes from d Pump Motor 3 Wiring to pump motor 3 Check for loose spray tu
22. D 3 z c rao B Self Contained Fan Motor FMS Pump Motor PM a S ot 8 ere 4 Pump Motor icemaking on at pump out only I 5 Pump Motor drain 6 Water Valve 7 10 Power line bin control 8 Open 5 4 m NN Water Valve WV ec 3 19 Es 5 Go 5 015 1 a 06 M6 o Compressor Comp d d C m EIN eeh Remote Fan Motor X M service boards only FMR Dee e Transformer Connector Control Board 2 1410 01 factory 2A1410 02 service HOS 001A Control Products 10 Pin 12 2 Features a Maximum Water Supply Period 6 minutes Inlet water valve opening in the harvest cycle is limited by the harvest timer The water valve cannot remain open longer than the maximum period The water valve can close in less than six minutes if the harvest cycle is completed b Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if for two cycles in a row the harvest cycle takes more than 20 minutes to complete The control board will signal this problem using 2 beeps every 3 seconds The freeze timer shuts down the icemaker if for two cycles in a row the freeze cycle takes longer than the time specified to complete The control board will signal this problem using 3
23. EEN Water Circuit 21 iagrams D iring B W E LZFY8Z OlSd E LZFZZE 9159 018 Dom 9JnsSaJg 1 300 031002 A INO 010 ngi 4000 mu 1 ug EPS YOLIVINOD INN um QuvOg Tm GHNZ62 72 dv LAVIS 31415 3178 IO MOTBA DW 3118 0 190 d AVAD AD NW 0 038 H We Jr M 038 ud 3005 4010 09 22 Performance Data 1 KML 451MAH air cooled APPROXIMATE ICE AMBIENT TEMP PRODUCTION PER 24 HR F C 70 21 80 27 90 32 lbs 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 24 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 Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 23 2 KML 451MWH water cooled APPROXIMATE ICE AMBIENT TEMP WATER TEMP F C PRODUCTION PER 24 HR F C 50 10 70 21 90 32 Ibs day k
24. Hoshizaki America Inc Low Profile Modular Crescent Cuber Models KML 45 MAH KML 45 SERVICE MANUAL A Superior Degree of Reliability www hoshizaki com N evercheck Number 73143 Issued 3 1 2007 IMPORTANT Only qualified service technicians should attempt to service or maintain this unit No such service or maintenance should be undertaken until the technician has thoroughly read this Service Manual HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the unit Should the reader have any questions or concerns which have not been satisfactorily addressed please call write or send an e mail message to the HOSHIZAKI Technical Support Department for assistance HOSHIZAKI AMERICA INC 618 Highway 74 South Peachtree City GA 30269 Attn HOSHIZAKI Technical Support Department Phone 1 800 233 1940 Technical Service 770 487 2331 Fax 1 800 843 1056 770 487 3360 E mail techsupport hoshizaki com Web Site www hoshizaki com NOTE To expedite assistance all correspondence communication MUST include the following information Model Number Serial Number Complete and detailed explanation of the problem Please review this manual It should be read carefully before the icemaker is serviced or maintenance operations are performed Only qualified service technicians should service and maintain the icemaker
25. acket 8 Install the new valve Remove the drier then place the new drier position Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG Check for leaks using nitrogen gas 140 PSIG and soap bubbles Evacuate the system and charge with refrigerant the nameplate for the required refrigerant charge 13 Connect the flare connections 14 Open the water supply line shut off valve 15 Check for water leaks 16 Replace the panels in their correct positions 7 17 Turn on the power supply 38 Adjustment of Water Regulating Valve Water Cooled Model Only The water regulating valve also called water regulator is factory adjusted No adjustment is required under normal use Adjust the water regulator if necessary using the following procedures 1 Prepare a thermometer to check the condenser drain temperature Attach a pressure gauge to the high side line of the system 2 Five minutes after a freeze cycle starts confirm that the thermometer reads 104 F to 115 F 40 C to 46 C If it does not rotate the adjustment screw by using a flat blade screwdriver until the temperature is in the proper range See Fig 1 Next check that the reference pressure is in the range indicated in the Head Pressure table in the Performance Data section If it is not in the proper range verify the refrigerant charge
26. ainer Place the new valve and strainer if applicable in position Remove the drier then place the new drier in position N 8 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG CAUTION 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 121 C 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 rating label inside the icemaker 11 Cut the leads of the solenoid allowing enough lead length to reconnect using closed end connectors 12 13 14 15 Connect the new solenoid leads Attach the solenoid to the valve body and secure it with the screw Replace the panels in their correct positions Turn on the power supply Removal and Replacement of Evaporator IMPORTANT Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repairs or replacement have been made 1 Turn off the power supply 3 2 Remove the panels and the top insulation over the evaporator Recover the refrigerant and store it in an approved container 4 Remove the spray tubes and the insulations at the U shaped notch
27. alve make sure the washer is in place in the fitting nut 8 9 0 1 Open the water supply line shut off valve Turn on the power supply 10 Check for leaks 1 SI Replace the panels in their correct positions 41 Removal and Replacement of Pump Motor 1 Turn off the power supply 2 Remove the front panel 3 Remove the three screws and the float switch assembly 4 Remove the wiring connectors from the pump motor leads 5 Disconnect the hoses attached to the pump motor assembly 6 Remove the four screws and the pump motor 7 Install the new pump and replace the removed parts in the reverse order of which they were removed 8 Turn on the power supply and check for leaks 9 Replace the front panel in its correct position 42 VI 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 A Cleaning and Sanitizing Procedures WARNING 1 HOSHIZAKI recommends cleaning this unit at least once a year More frequent cleaning however may be required in some existing water conditions 2 To prevent injury to individuals and damage to the icemaker do not use ammonia type cleaners 3 Always wear liquid proof gloves to prevent the cleaning and sanitizing solutions from coming into contact with skin 1 Cleaning Procedure 1 Dilute approximatel
28. as and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model RS43C2E CAA 219 Air Cooled Fin and tube type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R404A 1 Ib 13 1 oz 825g High 467PSIG Low 230PSIG High Voltage Cut out Internal Auto reset Overload Protector Internal Auto reset High Pressure Control Switch Float Switch N A Ice Storage Bin VOLTAGE RANGE 104 127V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 2 KML 451MWH 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 Ibs 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
29. beeps every 3 seconds The time is factory set using dip switches 9 amp 10 The reset button on the control board must be pressed with power on to reset either of these safeties c High Temperature Safety The temperature of the suction line in the refrigeration circuit is limited by the high temperature safety This protects the unit from excessively high temperatures If the evaporator temperature rises above 127 F 7 F 53 4 C the thermistor operates the safety This shuts down the circuit and the icemaker automatically stops The control board will signal this problem using 1 beep every 3 seconds The reset button on the control board must be pressed with power on to reset the safety d Low Water Safety The control board checks the position of the float switch at the end of the initial one minute water fill cycle and at the end of each harvest 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 For water cooled model if the condenser water supply is shut off the unit is protec
30. bes Water continued connection or open and pump will not start or replace freeze cycle time is 4 Defective capacitor 4 Replace too short continued 5 Defective or bound 5 Replace and clean impeller e Control Board 1 Defective 1 See 1 4 Control Board Check Procedure 6 Fan motor will a Fan Motor 1 Motor winding opened 1 Replace not start or is not operating 2 Bearing worn out 2 Replace 3 Wiring to fan motor 3 Check for loose connection or open and replace 4 Defective capacitor 4 Replace 5 Fan blade bound 5 Check and replace b Control Board 1 Defective 1 See 1 4 Control Board Check Procedure 7 All components a Refrigerant 1 Undercharged 1 Check for leaks and run but no ice is recharge produced 2 Air or moisture 2 Replace drier and trapped recharge b Compressor 1 Defective valve 1 Replace Hot Gas Valve 1 Continues to open 1 Check and replace freeze cycle d Line Valve 1 Continues to close 1 Check and replace if applicable freeze cycle e Inlet Water Valve 1 Water valve is wide 1 Check for water leaks with open during freeze icemaker off f Headmaster 1 Not operating properly 1 Replace headmaster remote air cooled and liquid line model temperature too warm 9 Water Supply Line 1 Condenser water 1 Check and get water cooled model pressure too low or off recommended pressure and pressure
31. ce switch has no power and can be left in any position a DRAIN The KML series utilizes a pump out drain system When the service switch is active and placed in the DRAIN position power is supplied to the pump and drain valve b CIRCULATE When the service switch is active and placed in the CIRCULATE position power is supplied to the pump only This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator c WASH The KML series utilizes a solenoid operated wash bypass valve When the service switch is active and placed in the WASH position power is supplied to the pump and wash valve This operation is used to circulate cleaner and sanitizer over both the inside and outside of the evaporator 19 Technical Information A Water Circuit and Refrigeration Circuit 1 KML 451MAH air cooled Condenser Spray Tube Water Valve High Pressure Switch Evaporator Heat Exchanger Strainer Switch Discharge Line Compressor L3 Access Valve Expansion Valve Refrigerant Circuit Water Circuit 20 2 KML 451MWH water cooled Water Regulating Condenser Valve Spray Tube Water Valve Evaporator High Pressure Switch Thermistor Drier Heat Exchanger Strainer Hot Gas Valve Discharge Line Compressor Access Expansion Valve Refrigerant Circuit mEm
32. cedure 3 Other a Spray Tubes 1 Clogged 2 Out of position 2 Place in position p Water System D D c Refrigerant 1 Undercharged 1 Check for leaks and recharge d Expansion Valve 1 Bulb out of position or 1 Place in position loose attachment 2 Replace e Hot Gas Valve 1 Coil winding opened 1 Replace 2 Plunger does not 2 Replace move 3 Wiring to hot gas 3 Check for loose valve connection or open and replace f Ice Cube Guide 1 Out of position and ice 1 Place in position trapped 30 Possible Cause 3 Other continued g Water Supply Line 1 Too small requires 1 Increase water line size 3 8 OD line dedicated per machine h Water Filter 1 Flow rate too small 1 Replace with filter that has larger flow rate 3 Low Ice Production Possible Cause 1 Freeze cycle time is a See chart 1 3 and check dirty air filter or condenser ambient or water long temperature water pressure condenser water regulating valve water cooled model and refrigerant charge b See chart 2 1 and check float switch inlet water valve and control board Check pump hot gas valve headmaster C P R remote air cooled model expansion valve refrigeration check valve and compressor 2 Harvest cycle time is a See chart 2 2 and check control board thermistor evaporator ambient and or water temperature water supply line inlet water valve line valve if applicable
33. cess valves and disconnect the service manifold hoses 10 Cap the access valves to prevent a possible leak 34 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 not mix lubricants of different compressors even if both are charged with R 404A except when they use the same lubricant 1 2 3 Turn off the power supply Remove the panels Recover the refrigerant and store it in an approved container S gt Remove the terminal cover on the compressor and disconnect compressor wiring O1 Remove the hold down bolts washers and rubber grommets Remove the discharge and suction pipes N Remove the compressor Unpack the new compressor package Attach the rubber grommets of the prior compressor 9 10 11 12 13 14 Place the compressor position and secure it using the bolts and washers Remove the drier then place the new drier in position Remove plugs from the suction discharge
34. control opens and closes frequently h Water Regulator 1 Set too high 1 Adjust or replace See water cooled model V G Adjustment of Water Regulating Valve 29 2 Evaporator is Frozen Up Possible Cause 1 Freeze cycle time is a Float Switch 1 Leads short circuit or 1 Check and replace too long defective switch 2 Float does not move 2 Clean or replace freely b Inlet Water Valve 1 Diaphragm does not 1 Check for water leaks with close icemaker off Control Board 1 Defective 1 See 1 4 Control Board Check Procedure 2 ice formed on a Evaporator 1 Scaled up evaporator does b Water Supply Line 1 Water pressure too 1 Check and get fall E bin in harvest low recommended pressure cycle c Water Filter System 1 Dirty Restricted 1 Replace filter d Inlet Water Valve 1 Dirty mesh filter or 1 Clean orifice 2 Diaphragm does not 2 Check for water leaks with close icemaker off e Ambient and or water 1 Too cool 1 Increase temperature PE Line Valve 1 Continues to open 1 Check operation in harvest applicable harvest cycle cycle and replace g Thermistor 1 Out of position or 1 See V I Removal loose attachment and Replacement of Thermistor h Control Board 1 Harvest timer is set 1 Adjust longer referring too short to II C 3 Controls and Adjustments b Harvest Timer 2 Defective 2 See II C 4 Control Board Check Pro
35. e unit remains in freeze with the float switch removed replace 25 the board Note Normal freeze cycle will last 20 to 40 minutes depending on model and conditions Cycle times and pressures should follow performance data provided in this manual 6 Pump Out Cycle 10 20 second pump out the compressor remains energized the hot gas valve energizes the fan motor de energizes the pump motor stops for 2 seconds The service relay energizes restarting the pump motor and taking water from the sump and forcing it to go through the drain valve and down the drain for 10 20 seconds This removes contaminants from the water reservoir Diagnosis If the pump motor does not run check the circuit service relay and capacitor Check for proper voltage If water does not pump out check and clean the tubing at the drain valve and then check and clean the valve assembly 7 Normal Harvest Cycle same as the initial harvest cycle Return to step 4 Note Unit continues to cycle until bin control is satisfied or power is switched OFF The pump out cycle can be adjusted to occur every cycle or every 2 5 or 10 cycles The factory default is every 10 cycles The unit always restarts at the 1 minute fill cycle B Diagnostic Charts 1 No Ice Production 1 The icemaker will not a Power Supply 1 OFF position 1 Move to ON position 3 Bad contacts 3 Check for continuity and replace 4 Voltage too high or too 4 Check and get lo
36. elp 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 Switches 1 2 5 amp 6 are cleaning adjustments and the settings are flexible 2 Turn the control switch to ICE and check for proper control voltage If the red LED is ON the control voltage is good If the red LED is OFF check the control transformer circuit 3 Check the 115 volt input at the 10 pin connector Check the brown wire at pin 10 to white neutral wire for 115 volts Always choose a white neutral wire to establish a good neutral connection when checking voltages A jumper also feeds 115 volts into pin 7 If no voltage is present check the 115 volt supply circuit 4 The output test switch provides a relay sequence test Make sure the control switch is in the ICE position then press the output test switch The correct lighting sequence should be none 2 3 4 1 Some components e g the compressor will cycle during the test Note that the order of the relays from the outer edge of the board is 1 4 3 2 If the LEDs light in a different sequence the control board is bad and should be replaced After the output test the unit automatically resumes normal operation at the 1 minute fill cycle 5 Control Board Replacement The application switch located between relay X3 amp X4 must be set to match the original board application Place this switch in the ALP position if there i
37. ent of 33 A Service for Refrigerant Lines eerste 33 UN Retrig rant e E 33 PM sirva e T E EUER 33 Evacuation and Recharge EE ENEE Ge 34 B Removal and Replacement of 35 C Removal and Replacement of Expansion Valve 36 D Removal and Replacement of Hot Gas Valve or Line Valve 36 E Removal and Replacement of 37 F Removal and Replacement of Water Regulating Valve Water Cooled Model Only 38 G Adjustment of Water Regulating Valve Water Cooled Model Only 39 H Removal and Replacement of Headmaster Condensing Pressure Regulator C P R Remote Air Cooled Model ny 39 I Removal and Replacement Of 40 J Removal and Replacement of Fan Motor 41 K Removal and Replacement of Water Valves ee 41 L Removal and Replacement of Pump 42 VI Cleaning and Maintenance InStubllOFiS 43 A Cleaning and Sanitizing ele 43 cla sol Procedure E 43 2 Sanitizing Procedure Following Cleaning
38. g day APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day m day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 6 400 BTU h AT 90 F 32 C WT 70 F 21 C TOTAL HEAT OF REJECTION FROM COMPRESSOR 1 100 BTU h AT 90 F 32 C WT 70 F 21 WATER FLOW FOR CONDENSER 48 gal h AT 100 F 38 C WT 90 F 32 C PRESSURE DROP OF COOLING WATER LINE less than 10 PSIG Note 1 Pressure data is recorded at 5 minutes into freezing cycle The data not in bold should be used for reference only 2 We reserve the right to make changes in specifications and design without prior notice 24 IV Service Diagnosis A 10 Minute Diagnostic Procedure The 10 minute check out procedure is basically a sequence check which can be used at unit start up or for system diagnosis Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 70 F or warmer air and 50 F or warmer water temperatures Before conducting a 10 minute checkout check for correct installation proper voltage per unit nameplate and adequate water supply As you go throug
39. h the procedure check to assure the components energize and de energize correctly If not those components and controls are suspect Check for voltage at the 10 pin connector 1 Turn power OFF and access the control box 2 Turn power ON and place the control switch in ICE position A 5 second delay occurs 3 One Minute Fill Cycle The inlet water valve is energized After 1 minute the control board checks the float switch If the float switch is closed the unit cycles to harvest If closed continue to step 4 If the float switch is open the unit repeats the 1 minute fill cycle until water enters and the float switch closes low water safety protection during initial start up and at the end of each harvest Diagnosis If the water valve does not open check for no supply voltage at water valve terminals bad coil or plugged screen or external filter no water flow If unit fails to start harvest check for open float switch or bad 1 minute timer in board 4 Initial Harvest Cycle Inlet water valve remains energized contactor coil energizes to start the compressor and fan motor on a remote condenser unit and the hot gas valve energizes The evaporator warms and the thermistor senses 48 F 9 C The control board then receives the thermistor s 3 9 kO signal and turns operation of harvest over to the harvest timer The timer completes counting 1 to 3 minutes The unit then cycles to freeze Diagnosis Check if compressor is running
40. he ambient temperature is below 45 F 7 C 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 continuously even if the ice storage bin is filled with ice Setting in the prohibited range might cause severe damage to the icemaker resulting in failure No adjustment is required under normal use as the bin control is factory adjusted Adjust it if necessary so that the icemaker stops automatically within 10 seconds after ice contacts the bin control thermostat bulb F Switches Two control switches are used to control operation in the KML Series Modular Crescent Cubers These switches are referred to as the control switch and the service switch and are located on the control box 1 Control Switch The control switch has three positions OFF for power off ICE for icemaking and SERVICE to activate the service switch 18 2 Service Switch When the control switch is in the SERVICE position the control switch supplies power to the service switch and the machine is in service mode The service switch has three positions DRAIN CIRCULATE and WASH See the information below for details of each function Note 1 When the service switch is activated power is supplied to the water pump in all three positions 2 When the control switch is in the OFF position or in the ICE position the servi
41. he power supply after 3 minutes 22 Remove the front panel 23 Place the control switch in the SERVICE position Then place the service switch in the WASH position 24 Replace the front panel in its correct position 25 Turn on the power supply to rinse off the cleaning solution 26 27 28 Move the service switch to the DRAIN position Turn off the power supply after 5 minutes Remove the front panel 29 Replace the front panel in its correct position and turn on the power supply for 2 minutes 30 Turn off the power supply 31 Remove the front panel 32 Repeat steps 18 through 31 three more times to rinse thoroughly Note If you do not sanitize the icemaker go to step 14 in 2 Sanitizing Procedure 2 Sanitizing Procedure Following Cleaning Procedure 1 Dilute approximately 1 fl oz 30 ml of a 5 25 sodium hypochlorite solution chlorine bleach with 2 gallons 7 6 1 of warm water 2 Remove the insulation panel 3 Pour the sanitizing solution into the water tank 4 Move the service switch to the WASH position 5 Replace the insulation panel and the front panel in their correct positions 6 Turn on the power supply and start the sanitizing process 7 Turn off the power supply after 15 minutes 8 Remove the front panel 9 Move the service switch to the DRAIN position 10 Replace the front panel in its correct position and turn on the power supply for
42. hing of the control box to the K3 connector on the control 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 J 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 6 Install the new fan motor and replace the removed parts in the reverse order of which they were removed 7 Replace the panels in their correct positions 8 Replace the junction box cover in its correct position remote air cooled model 9 Turn on the power supply K Removal and Replacement of Water Valves 1 2 3 A Turn off the power supply Close the water supply line shut off valve Remove the panels Remove the tubing attached to the valve If replacing the inlet water valve loosen the fitting nut Be careful not to lose the washer 5 Disconnect terminals from the water valve 6 Remove the bracket and valve from the unit 7 Install the new water valve Replace the removed parts in the reverse order of which they were removed If replacing the inlet water v
43. ition Circulated water falls into bin 32 V Removal and Replacement of Components IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after the equipment is serviced 2 The Polyol Ester POE oils used in R 404A units can absorb moisture quickly Therefore it is important to prevent moisture from entering the system when replacing or servicing parts 3 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 Do not leave the system open for longer than 15 minutes when replacing or servicing parts A Service for Refrigerant Lines WARNING 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 trace of refrigerant raising the pressure with nitrogen and using an electronic leak detector 1 Refrigerant Recovery The icemaker unit is provided with refrigerant access valves 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 2 Brazing WARNING Refrigerant 404 itself is not flammable at atmospheric pressure and temperatures up to 176 F 80 C Refrigerant 404 itself is not explosive or poisonous However when exposed to high temperatures open flames R 404A ca
44. larm i Hot Gas Valve 1 Continues to open 1 Check for hot gas valve in freeze cycle and stuck open and replace freeze timer safety operates 3 beep alarm j Water Supply Line 1 Water supply off and 1 Check and get water supply cycle recommended pressure does not finish 2 Condenser water 2 Check and get pressure too low recommended pressure or off and pressure control opens and closes frequently to finally operate high temperature safety 1 beep alarm k Inlet Water Valve 1 Mesh filter or orifice 1 Clean gets clogged and water supply cycle does not finish 2 Coil winding opened 2 Replace 3 Wiring to water valve 3 Check for loose connection or open and replace 1 Control Board 1 Defective or in alarm 1 1 4 Control Board Check Procedure 27 1 The icemaker will not m Control Switch 1 SERVICE position 1 Move to ICE position start continued 2 Check and replace 2 Water continues to a Float Switch 1 Connector 1 Place in position be supplied and the disconnected icemaker will not 2 Leads opened or 2 Check and replace start defective switch 3 Float does not move 3 Clean or replace freely b Control Board 1 Defective 1 See 1 4 Control Board Check Procedure 3 Compressor will a Magnetic Contactor 1 Bad contacts 1 Check for continuity and not start or stops replace operating 2 Coil winding opened 2 Replace b Start
45. m overheating Do not braze with the valve body exceeding 250 F 121 C 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 rating label inside the icemaker 10 Attach the expansion valve bulb to the suction line in the same location as the previous bulb The bulb should be at the 12 o clock position on the tube Be sure to secure the bulb with the clamp and holder and to insulate it 11 Place the new set of expansion valve cover in position 12 Replace the panels in their correct positions 13 Turn on the power supply D Removal and Replacement of Hot Gas Valve or Line Valve IMPORTANT 1 Always use a copper tube of the same diameter and length when replacing the hot gas lines otherwise the performance may be reduced 2 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 3 Always replace the strainer when replacing the hot gas valve 36 1 Turn off the power supply Remove the panels ao Recover the refrigerant and store it an approved container Remove the screw and the solenoid Disconnect the valve If replacing the hot gas valve also remove the str
46. n be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous 3 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 trace of refrigerant raising the pressure with nitrogen and using an electronic leak detector 1 Always install a new drier every time the sealed refrigeration system is opened Do not replace the drier until after all other repair or replacement has been made Install the 33 new drier with the arrow the drier in the direction of the refrigerant flow 2 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 3 Check for leaks using nitrogen gas 140 PSIG and soap bubbles Do not use R 404A as a mixture with pressurized air for leak testing Note Because the pipes in the evaporator case are specially coated to resist corrosion it is important to make connections outside the evaporator case when possible If it is necessary to braze inside the evaporator case use sandpaper to remove the coating from the brazing connections before unbrazing the components 3 Evacuation and Recharge R 404A 1 Attach a vacuum pump to the system Be sure to connect charging hoses to both high and
47. omp PM 5 minutes freeze timer 30 to 35 minutes FMR FMS setting LLV 3 and 2 HGV factory setting The built in safeties shut down the unit and have alarms as follows Type of Alarm Notes High Evaporator Temp Check for harvest problem stuck HGV or temperature gt 127 F relay hot water entering unit stuck HM 53 C or shorted thermistor Harvest Backup Timer Orange LED marked H TIMER lights up harvest gt 20 min for two Check for open thermistor HGV not cycles in a row opening TXV leaking by low charge or inefficient compressor Freeze Timer Yellow LED marked F TIMER lights up freeze gt specified setting Check for F S stuck closed up WV for two cycles in a row leaking by HGV leaking by TXV not Timer is factory set using feeding properly low charge HM dip switches 9 amp 10 bypassing or inefficient compressor To manually reset the above safeties press the alarm reset button with the power supply on Low Voltage Red LED will turn off if voltage protection 92Vac 5 or less operates High Voltage The control voltage safeties automatically 147Vac 5 or more reset when voltage is corrected Legend Comp compressor DV Drain Valve FWR remote fan motor FMS self contained fan motor F S float switch HGV hot gas valve HM headmaster C P R LLV Liquid Line Valve PM pump motor SR Service Relay TXV thermostatic expansion valve WV inlet
48. rect positions 13 Turn on the power supply Removal and Replacement of Thermistor IMPORTANT 1 Fragile handle very carefully 2 Always use a recommended sealant high thermal conductive type Model KE4560RTV manufactured by SHINETSU SILICONE Part Code 60Y000 11 or Part Code 4A0683 01 or equivalent 3 Always use a recommended foam insulation non absorbent type or equivalent 4 Do not shorten or cut the thermistor leads when installing 1 Turn off the power supply 2 3 4 Disconnect the thermistor leads from the connector on the control board Thermistor Lead Cable Tie Remove the panels Remove the control box cover 5 Remove the plastic cable ties foam insulati CH insulation thermistor holder and thermistor See Fig 2 GE Up 6 Scrape away the old sealant on the Foam Insulation Thermistor Holder thermistor holder and the suction pipe 7 Wipe off moisture or condensation on the Fig 2 suction pipe 8 Smoothly apply recommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the thermistor holder concave 40 9 Attach the new thermistor to the suction pipe in the same position as the previous thermistor Be very careful to prevent damage to the leads Secure it using the thermistor holder and recommended foam insulation 10 Secure the insulation using the plastic cable ties 11 Connect the thermistor leads through the bus
49. s 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 energized with the control switch OFF or the unit will not start The dip switches should be adjusted to the factory default settings as outlined in this manual 8 must remain in the OFF position 17 D Harvest Control Thermistor A thermistor Semiconductor is used for a harvest control sensor The resistance varies depending on the suction line temperatures The thermistor detects the temperature of the evaporator outlet to start the harvest 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 14 401 ___ 2 ______ 10673 6 000 2 474 1 633 12 10 21 32 387 Check thermistor for resistance by using the following procedure 1 Disconnect the connector K3 on the board 2 Remove the thermistor See V I Removal and Replacement of Thermistor 3 Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes 4 Check for a resistance between thermistor leads Normal reading is within 3 5 to 7 kQ Replace the thermistor if it exceeds the normal reading E Bin Control CAUTION When t
50. sembly if it goes bad Do not short out power supply to test for voltage 11 1 Control Board Layout Control Products E Control Board Output Test Switch EE Dip Switch used to test relays on board ALARM RESET OUTPUT TEST a 00089810E Backup Freeze Timer LED Connector K3 Harvest Control thermistor WHITE Backup Harvest soe Timer LED GE 2 not connected o iz Microprocessor board revision level indicated by last 2 digits on label Alarm Buzzer Power LED lights when power is supplied to the board o BLACK d N N P N 2 1410 01 Relay LEDs 4 Connector K5 indicate which E E gt Float Switch relays are energized ent Se as listed below tr lo ET Part Number LED 2 RHO it Connector K1 Hot Gas Valve HGV gt LH 3 Pins 1 through 10 Self Contained Fan E 9 4H 9 Magnetic Contactor Motor FMS FMS 2H ste 2 Hot Gas Valve off when LED on s 9 09 ete 3 Line Valve LE
51. ted by the high pressure switch e High Voltage and Low Voltage Cut outs The maximum and minimum allowable supply voltages of this icemaker are limited by the high voltage and low voltage cut outs If miswiring especially on single phase 3 wire models causes excessive voltage 147Vac 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 92Vac 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 13 f 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 OFF The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below Note that the order of the LEDs from the outer edge of the board is 1 4 3 2 For more information see Sequence of Operation Energized Time LEDs are On Sequence Step erg Components Min awa 1 Minute Fill Cycle 4 WV ______________60 seconds FMR Freeze Cycle C
52. tor located on the suction line checks for a 48 F 9 C temperature When 48 F 9 C is reached a 3 9 signal turns the harvest over to the adjustable harvest timer which is factory set for normal conditions The timer has settings of 60 90 120 and 180 seconds dip switch 1 amp 2 The water valve is open during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter When the harvest timer completes its count down the harvest cycle is complete and the freeze cycle starts The minimum total time allowed by the board for a complete harvest cycle is 2 minutes Freeze Cycle LED 1 is on Comp and FMR continue to run PM and FMS energize LLV opens HGV and WV close and the freeze cycle starts For the first 5 minutes the control board will not accept a signal from F S This 5 minute minimum freeze acts as a short cycle protection At the end of 5 minutes F S assumes control As ice builds on the evaporator the water level in the sump lowers The freeze continues until F S opens and terminates ice production Pump Out Cycle LEDs 1 3 and 2 are on Comp and FMR continue to run HGV opens LLV closes and FMS de energizes PM stops for 2 seconds SR energizes restarting PM and taking water from the sump and forcing it to go through DV and down the drain When the pump out timer stops counting the pump out is complete Pump out always occurs on the 2nd harvest after startup Then depending on the control
53. uired depending on the location of the icemaker or condenser unit C Preparing the Icemaker for Long Storage CAUTION 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 using air or carbon dioxide to prevent damage to the water supply line at sub freezing temperatures 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 temperatures 45 1 On water cooled model only first remove the water from the water cooled condenser 1 Turn off the power supply 2 Remove the front panel 3 Move the control switch on the control box to the OFF position 4 5 Move the control switch to the ICE position 6 7 8 Close the water cooled condenser water supply line shut off valve Wait 3 minutes Replace the front panel and turn on the power supply Allow 5 minutes for the icemaker to fill with water and the water pump to start operating 9 Open the drain valve for the water cooled condenser water supply line 10 Allow the line to drain by gravity 11 Attach compressed air or carbon dioxide supply to the condenser water line drain valve 12 Blow the water cooled condenser out
54. w recommended voltage b Fuse Inside fused 1 Blown 1 Check for short circuit and disconnect if any replace c Control Switch 1 OFF position 1 Move to ICE position 2 Bad contacts 2 Check for continuity and replace d Bin Control Thermostat 1 Tripped with bin filled 1 Remove ice with ice 2 Ambient temperature 2 Increase ambient too cool temperature 3 Set too warm 3 See Bin Control 4 Bulb out of position 4 Place in position 5 Bad contacts 5 Check for continuity and replace e High Pressure Control 1 Bad contacts 1 Check for continuity and replace 2 Dirty air filter or 2 Clean condenser 26 1 The icemaker will not High Pressure Control 3 Ambient or condenser 3 Reduce temperature start continued continued water temperature too warm 4 Refrigerant 4 Recharge overcharged 5 Fan not operating 5 See chart 1 6 except water cooled model 6 Refrigerant line or 6 Clean and replace drier components plugged 7 Condenser water 7 Check and get pressure too low or off recommended pressure water cooled model f Transformer 1 Coil winding opened 1 Replace or shorted g Wiring to Control Board 1 Loose connections or 1 Check for continuity and open replace h Thermistor 1 Leads shorted or 1 See Harvest Control opened and high Thermistor temperature or harvest backup timer safety operates 1 beep or 2 beep a
55. y 10 5 fl oz 310 ml of Hoshizaki Scale Away with 2 gallons 7 6 1 of warm water 2 Remove all ice from the evaporator and the storage bin Note To remove cubes on the evaporator turn off the power supply and turn it on after 3 minutes The defrost cycle starts and the cubes will be removed from the evaporator 3 Turn off the power supply 4 Remove the front panel 5 Place the control switch in the SERVICE position Then place the service switch in the DRAIN position 6 Replace the front panel in its correct position and turn on the power supply for 2 minutes 7 Turn off the power supply 8 Remove the front panel and then remove the insulation panel by lifting up the panel slightly and pulling it towards you 9 Pour the cleaning solution into the water tank 10 Move the service switch 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 43 15 Move the service switch to the DRAIN position 16 Replace the front panel in its correct position and turn on the power supply for 2 minutes 17 Turn off the power supply and remove the front panel 18 Move the control switch to the ICE position 19 Replace the front panel in its correct position 20 Turn on the power supply to fill the water tank with water 21 Turn off t
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