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Hoshizaki KM-2500SRH3 User's Manual

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2. 31249 1n o duing p HHSO00SC INX HMSOOSC INM yeys MOL eouenbes peog 104002 3 2 Sequence Flow Chart a 0J u09 UI 10191 p gt AA 31949 III einurN L 0 suunjei y pue sdojs 10sse1dujoo uado si 9 4 11 u do S 4 pezi amp ueue AM S d ajoA9 Iz enuny r 7L lt q Ke op 295 Joye suifeq dnueis sdeis l 42 lt P C Control Board A Hoshizaki exclusive control board is employed in KM 25008WH3 and KM 2500SRH3 Stackable Crescent Cubers All models are pretested and factory adjusted For a control board check procedure see IV B Control Board Check CAUTION 1 The control board is fragile handle very carefully 2 The control board contains integrated circuits which are susceptible to failure due to static discharge It is especially important to touch the metal part of the unit before handling or replacing the control board Do not touch the electronic devices on the control board or the back of the control board Do not change wiring and connections Do not misconnect K3 K4 and K5 because the same connector is used for the thermistor and float switch K4 is not connected 5 Always replace the whole control board assembly if it goes bad 6 Do not short out power supply to test for voltage 1 Control Board Layout E Control Board ALARM RESET Button S4 Dip Switch OUTPUT
3. 1 Ke RS EN EN im Aiddns OD Joyeiodeng i ru ri Jasuapuog Addne JajeM A BA 23 2 KM 2500SRH3 remote air cooled UO Joe mm uonejeBujeH S A BA xoeuo r 4 urens Bnid adem YAMS L eansseJq u6ir JO SIU49U A BA eur p nb rI eave Buiuee 2 SS Joyesoden gag ees JejseuipeeH Ajuo esr Hope Jeug HAIBA HO INYS J su puo5 24 B Wiring Diagrams 1 KM 2500SVVH3 water cooled KM 2500SRH3 remote air cooled 0154 12 26 0154 1282 un 9124 2521 DIS iz v8 pajoo3 1918A 5 Uu91IMS ounssaJd YIH ISVOMNWYD KINO 310838 AINO 31038 MOTIJA UO A 1018 Wava 60 WI d M 49 191010 0 034 u UI 0 UI WI IO ug no TORINO m 0000761 D I 8 R ig y ASLI YE AS OL y ndino 1euujoJsueJ K M n 1 17 MN DENS MM Ww 6 amp 2 i ish m E E IN Wm o mpm n 1 YA un mu JAWA ul JAWA 3861 JAWA S 9LOH WI 4 WK BM e To S ni tol d 1080 I toll M to or ul d to Sou D mm H dert ig fei WS di m 1 4 3
4. 3 Fan Motor FM on at pump out only 29 M Brus S Liquid Line Valve LLV EI Ero EE UE 4 Pump Motor icemaking LED 4 X4 TEL Te Ze 5 Pump Motor pump out Inlet Water Valve WV zane 6 Inlet Water Valve WV S og En 7 nh 7 10 Component Power LED 1 X1 Relay e a Supply Compressor ST An 8 Open on LUN O E s o Switch for C Control Board FMR td ae R iX and ALPINE Control Board Ka Corrector service boards only Transformer E Control Board Part Number 2A1410 01 factory 2A1410 02 service 16 2 Features a Maximum Water Supply Period 6 minutes The inlet water valve remains energized during harvest for 6 minutes or the length of harvest whichever is shorter b Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if for two cycles in a row the harvest cycle takes more than 20 minutes to complete The control board signals with the H Timer LED and 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 by the freeze timer S4 dip switch 9 amp 10 The control board signals with the F Timer LED and 3 beeps every 3 seconds The freeze timer is factory set and no adjustment is required To reset either of these safeties press the ALARM RESET button on the control board with power on c High Temperature Safety The temperature of t
5. d Pump Out Cycle LEDs 1 3 and 2 are on LED 4 is on when S4 dip switch 3 amp 4 are set to 3 off and 4 on Comp and FMR remain energized HGV energizes LLV de energizes WV energizes if S4 dip switch 3 amp 4 are set to 3 off and 4 on PM stops for 2 seconds then reverses taking water from the bottom of the tank and forcing pressure against the check valve seat allowing water to go through the check valve and down the drain At the same time water flows through the small F S tube to power flush F S When the pump out timer S4 dip switch 3 amp 4 terminates pump out is complete The first pump out occurs after the first freeze cycle and every cycle thereafter The pump out frequency control is factory set to drain the water tank every cycle and generally no adjustment is required The pump out frequency control S4 dip switch 5 amp 6 can be set to have a pump out occur every cycle or every 2 5 or 10 cycles For details see 11 4 4 Pump Out Frequency Control S4 Dip Switch 5 amp 6 e Harvest Cycle Same as the initial harvest cycle See II B 1 b Initial Harvest Cycle Note Unit continues to cycle until BC is satisfied or power is turned off The unit always restarts at the 1 minute fill cycle f Shutdown When ice contacts the thermostatic bulb BC switch open BC shuts down the unit within 10 seconds BC is factory set and generally no adjustment is required However adjustment may be needed in some conditions
6. 1 2 3 4 5 6 7 8 9 10 Freeze Timer 9 amp 10 Factory Use 8 Bin Control Selector 7 Pump Out Frequency Control 5 amp 6 Pump Out Timer 3 amp 4 Harvest Timer 1 amp 2 b Harvest Timer S4 dip switch 1 amp 2 The harvest timer starts when the thermistor warms to 48 F 9 C at the evaporator outlet and the control board reads the thermistor s 3 9 kO signal The harvest timer is factory set and generally no adjustment is required 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 contact Hoshizaki Technical Support at 1 800 233 1940 for recommendations Keep in mind that setting the harvest timer to a longer setting will decrease 24 hour production Note that the pump out timer S1 dip switch 3 amp 4 acts in place of the harvest timer during cycles with a pump out For details see Il C 4 c Pump Out Timer S1 dip switch 3 amp 4 S4 Dip Switch Setting Time No 1 No 2 seconds ore ore o ON OFF 90 c Pump Out Timer S4 dip switch 3 amp 4 When a pump out is called for the pump motor stops after the preceding freeze cycle The pump motor energizes 2 seconds later in the reverse direction taking water from the bottom of the tank and forcing pressure against the check valve seat allowing water to go through the check valve and down the
7. 2 R 404A itself is not explosive or poisonous However when exposed to high temperatures open flames R 404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous 3 Do not use silver alloy or copper alloy containing arsenic 4 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 1 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 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 CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 2 Use an electronic leak detector or soap bubbles to check for leaks Add
8. Be careful not to bend the retainer rod YA excessively when removing it Rubber Boot and Hose EL Fig 2 33 7 Wipe down the float switch assembly s housing shaft float and retainer rod with a mixture of 1 part Hoshizaki Scale Away and 25 parts warm water Clean the inside of the rubber boot and hose with the cleaning solution Rinse the parts thoroughly with clean water 8 Reassemble the float switch assembly and replace it and the rubber boot in their correct positions Reconnect the vent tube and the flush tube 9 Move the control switch to the ICE position 10 Replace the insulation panel and front panel in their correct positions E Thermistor Check To check thermistor resistance follow the steps below 1 Turn off the power supply 2 Remove the front panel then move the control switch to the OFF position 4 Remove the thermistor See V K Removal and Replacement of Thermistor 5 Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 minutes 6 Remove the white thermistor connector from the control board WHITE K3 connector and check the resistance between thermistor leads Normal reading is within 4 7 to 6 2 kQ If outside the normal reading replace the thermistor If inside the normal reading continue to the next step 7 Replace the thermistor in its correct position See V K Removal Replacement of Thermistor 8 Reconnect the white thermistor co
9. Check that WV remains energized Comp FMR and HGV energize 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 Comp discharge line Is it hot If not check that Comp is energized refrigerant pressures are in range and Comp is efficient If it is hot place a thermometer on the suction line next to the thermistor Has it warmed to 48 F 9 C If not check that the HGV is energized and open On water cooled model check that WRV is not leaking by If temperature has been reached and the freeze cycle fails to start if not yet confirmed confirm thermistor status See IV E Thermistor Check If the thermistor reading is in proper range and CB fails to terminate the harvest cycle CB is bad and must be replaced 5 Freeze Cycle LED 1 is on Comp and FMR remain energized PM and LLV energize WV and HGV de energize The unit is held in freeze by a 5 minute short cycle protection timer CB will not accept a signal from F S After the 5 minute short cycle protection timer terminates CB turns freeze termination over to F S Diagnosis During the first 5 minutes of freeze confirm the evaporator temperature drops If the evaporator is not cold confirm that WV and HGV are closed and TXV is operating properly Next check for proper refrigerant pressures inefficient Comp or headmaster sticking remote air cooled After 5 minutes in freeze disconne
10. It is especially important to touch the metal part of the unit before handling or replacing the control board 3 Do not touch the electronic devices on the control board or the back of the control board 4 Do not change wiring and connections Do not misconnect K3 K4 and K5 because the same connector is used for the thermistor and float switch K4 is not connected 5 Always replace the whole control board assembly if it goes bad 6 Do not short out power supply to test for voltage 1 Turn off the power supply 2 Remove the front panel and the control box cover 3 Disconnect the control board connectors from the control board 4 Remove the control board 5 Adjust the dip switches on the new control board to the factory default settings See 4 Default Dip Switch Settings CAUTION Do not adjust S4 dip switch 7 out of the factory default position on this model This dip switch must be left in the factory default position or this unit will not operate correctly 6 Install the new control board taking care not to damage it 8 9 Turn on the power supply 7 Connect the control board connectors to the new control board Replace the control box cover and front panel in their correct positions 56 VI Cleaning and Maintenance IMPORTANT Ensure all components fasteners and thumbscrews are securely in place after any cleaning or maintenance is done to the equipment A Cleaning and
11. 115 60 1 Connection to Icemaker 115 V Total 2 6FLA 130W 46 3 8 x 15 11 16 x 25 15 16 1178 x 398 x 659 mm 48 7 16 x 18 1 8 x 40 7 8 1230 x 460 x 1039 mm Galvanized Steel Net 158 Ibs 72 kg Shipping 169 lbs 77 kg Permanent Connection Discharge Line 1 1 16 12 UNF Fitting 10 AEROQUIP Liquid Line 5 8 18 UNF Fitting 6 AEROQUIP Air cooled Fin and tube type Thermal Protection Condensing Pressure Regulator In Ice Machine R 404A 91b 1102 44009 High 467 PSIG 32 2 Bar VOLTAGE RANGE 104 127 V AMBIENT TEMP 20 122 F Leg 2 pcs Hex Head Bolt w Washer 8 x 16 8 pcs Hex Nut 8 8 pcs Note We reserve the right to make changes in specifications and design without prior notice Il General Information A Construction 1 KM 2500SVVH3 water cooled Spray Tubes Inlet Water Valve Water Supply Inlet Expansion Valves Check Valves Refrigeration Circuit CE Junction Box 4 Hot Gas Valve HA SZ Z Strainer YA 2 YA FT f Water A Regulating Valve Check Valve water Control Box Service Valves MT Condenser Drier Water Pump Float Switch un Cleaning Valve Liquid Line Valve Main Transformer Compressor Box Bin Control Thermostat Control Switch Bin Control Bulb Holder Bin Control Z Bracket Bin Control Extension Bracket Bin Contr
12. Steel Exterior To prevent corrosion wipe the exterior occasionally with a clean soft cloth Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up 2 Storage Bin and Scoop Wash your hands before removing ice Use the plastic scoop provided bin accessory The storage bin is for ice use only Do not store anything else in the storage bin Clean the scoop and the storage bin liner using a neutral cleaner Rinse thoroughly after cleaning 3 Condenser remote air cooled model only Check the condenser once a year and clean the coil if required by using a brush or vacuum cleaner More frequent cleaning may be required depending on location C Preparing the Icemaker for Long Storage CAUTION 1 When storing the icemaker for an extended time or in sub freezing temperatures follow the instructions below to prevent damage 2 To prevent damage to the water pump seal do not operate the icemaker with the control switch in the WASH position when the water tank is empty When the icemaker is not used for two or three days it is sufficient to only move the control switch to the OFF position unless the icemaker will be at sub freezing temperatures 1 Remove the water from the icemaker water supply line 1 Turn off the power supply then remove the front panel 2 Close the icemaker water supply line shut off valve and open the icemaker water supply line drain valve 3 Allow the line to drain by g
13. a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 3 Evacuation and Recharge R 404A 1 Attach a vacuum pump to the system Be sure to connect the charging hoses to both high and low side service 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 Open the gauge manifold valves Then open the high and low side service valves Never allow the oil in the vacuum pump to flow backwards 3 Allow the vacuum pump to pull down to a 29 9 Hg vacuum Evacuating period depends on pump capacity 44 4 Close the low side valve and high side valve on the gauge manifold 5 Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder Remember to loosen the connection and purge the air from the hose For water cooled model see the nameplate for the required refrigerant charge For remote air cooled model see the rating label inside the icemaker Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 latest edition be used 6 A liquid charge is required when charging an R 404A system to prevent f
14. compressor 2 Check for loose connection or open and replace 3 Defective 3 Replace 4 Protector tripped 4 Reduce temperature f Control Board 1 No power to contactor 1 See IV B Control Board Check 4 Water continues to a Water Pressure 1 Too high be supplied in freeze b Inlet Water Valve 1 Diaphragm does not 11 Check for water leaks with cycle close icemaker off c Control Board 1 Defective 1 See IV B Control Board Check 5 Pump motor will not a Pump Motor 1 Motor winding open 1 Replace start 2 Bearing worn out 2 Replace 3 Wiring to pump motor 3 Check for loose connection or open and replace 4 Defective capacitor 4 Replace 5 Defective or bound 5 Replace and clean impeller 6 Mechanical seal worn 6 Check and replace out b Control Board 1 Defective 1 See IV B Control Board Check c Control Switch 1 Replace 6 Freeze cycle time is a Pump Out Check Valve 1 Leaking 1 Clean or replace too short b Float Switch 1 Dirty or erratic 1 Clean or replace operation c Control Board 1 Defective 1 See IV B Control Board Check d Water System 1 Water leaks 1 Check connections for water leaks and replace 7 Fan motor will a Fan Motor 1 Motor winding open 11 Replace not start or is not 2 Bearing worn out 2 Replace operating except 7 model 3 Wiring to fan motor 3 Check for loose l connection or open and replac
15. control box to the VVASH position 11 12 13 14 15 Replace the insulation panel and the front panel in their correct positions Turn on the power supply to start the washing process Turn off the power supply after 30 minutes Remove the front panel and the insulation panel o Remove the cap located on the front bottom part of the ice dropping hole Drain the vvater tank Replace the cap and the insulation panel in their correct positions 16 Move the control svvitch to the ICE position 17 Close the cleaning valve Note The icemaker vvill not operate unless the cleaning valve is completely closed 58 18 Replace the front panel in its correct position 19 Turn on the power supply to fill the water tank with water 20 Turn off the power supply after 3 minutes 21 Remove the front panel and fully open the cleaning valve 22 Move the control switch to the WASH position 23 Replace the front panel in its correct position 24 Turn on the power supply to rinse off the cleaning solution 25 Turn off the power supply after 5 minutes 26 Remove the front panel and the insulation panel 27 Remove the cap located on the front bottom part of the ice dropping hole Drain the water tank Replace the cap and the insulation panel in their correct positions Note Do not replace the insulation panel when you proceed to 2 Sanitizing Procedure 28 Repeat steps 16 through 27 three more times to r
16. except 1 Bearings worn out 1 Replace water cooled model 5 Fan blade deformed 2 Replace 3 Fan blade does not 3 Replace move freely c Compressor 1 Bearings worn out or 1 Replace cylinder valve broken 2 Mounting pad out of 12 Reinstall position d Refrigerant Lines 1 Rub or touch other 1 Reposition lines or surfaces 3 Ice in storage bin a Drain Line s 1 Plugged often melts b Icemaker and Bin 1 Drains not run 1 Separate the drain lines separately c Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin 42 V Removal and Replacement of Components A WARNING 1 This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death electric shock serious injury or fire 2 Move the control switch to the OFF position and turn off the power supply before servicing CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after the unit is serviced Make sure that none have fallen into the storage bin Make sure all food zones in the icemaker and storage bin are clean after the unit is serviced For cleaning procedures see VI Cleaning and Maintenance A Service for Refrigerant Lines A WARNING 1 Repairs requiring the refrigeration circuit to be opened must be performed by properly trained and EPA certified service personnel 2 Always recover the refrigerant and
17. front panel and then remove Separator the insulation panel by first removing the thumbscrew lifting up the panel slightly and Cube Guide pulling it towards you z n Inside of Ice 5 Remove the cap located on the front Dropping Hole bottom part of the ice dropping hole Drain the water tank See Fig 6 6 Replace the cap in its correct position Be x Fig 6 careful not to cross thread it 7 In bad or severe water conditions clean the float switch assembly as described below Otherwise continue to step 8 a Disconnect the vent tube and the flush tube from the top of the float switch then remove the float switch assembly from the mounting bracket and remove the rubber boot from the bottom of the assembly b Remove the retainer rod from the bottom of the float switch assembly then remove the float Be careful not to bend the retainer rod excessively when removing it c Wipe down the float switch assembly s housing shaft float and retainer rod with cleaning solution Clean the inside of the rubber boot and hose with cleaning solution Rinse the parts thoroughly with clean water d Reassemble the float switch assembly and replace it and the rubber boot in their correct positions Reconnect the vent tube and the flush tube 8 Pour the cleaning solution into the water tank 2 Fully open the cleaning valve on the left side wall of the machine compartment o Move the control svvitch on the
18. has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the valve body and drier by using wet cloths to prevent the valve body and drier from overheating Do not allow the drier to exceed 250 F 121 C IMPORTANT Sometimes moisture in the refrigeration circuit exceeds the drier capacity and freezes up at the expansion valve 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 8 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 46 9 Evacuate the system and charge it with refrigerant For water cooled model see the nameplate for the required refrigerant charge For remote air cooled model see the rating label inside the icemaker 10 Attach the expansion valve bulb to the suction line in the same location as the
19. previous bulb The bulb should be placed between the 10 o clock and 2 o clock position on the tube Be sure to secure the bulb with the clamp and holder and to insulate it 11 Place the expansion valve cover in position 12 Replace the panels in their correct positions 13 Turn on the power supply D Removal and Replacement of Hot Gas Valve or Liquid Line Valve CAUTION 1 Always use a copper tube of the same diameter and length when replacing the valve lines otherwise performance may be affected 2 Always replace the strainer when replacing the hot gas valve 3 Always install a new drier every time the sealed refrigeration system is opened 4 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 5 When brazing protect the valve body and drier by using wet cloths to prevent the valve body and drier from overheating Do not allow the drier to exceed 250 F 121 C 1 Turn off the power supply 2 Remove the panels 3 Recover the refrigerant and store it in an approved container 4 Remove the bolt and the solenoid 6 Place the new valve and strainer if applicable in position 7 Remove the drier then place the new drier in position 8 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 9 Use an electronic leak detector or soap bubbles to check for le
20. step 4 If open WV remains energized through additional 1 minute fill cycles until water fills the tank and closes F S low water safety Diagnosis If WV does not open check for 115VAC at WV terminals If 115VAC is not present CB is defective and must be replaced If 115VAC is present check continuity of WV coil confirm the screen or external filter is not plugged no water flow If unit fails to start harvest check for open F S or bad 1 minute timer in CB See IV D Float Switch Check and Cleaning and IV B Control Board Check 28 4 Initial Harvest Cycle LEDs 1 4 and 2 are on WV remains energized Comp FMR and HGV energize WV is energized during harvest for a maximum of six minutes or the length of harvest which ever is shorter LED 4 goes off when WV de energizes CB monitors the warming of the evaporator via the thermistor located on the suction line When the thermistor warms to 48 F 9 C CB reads a 3 9 kO signal from the thermistor and turns harvest termination over to the harvest timer S4 dip switch 1 amp 2 The harvest timer has settings of 60 90 120 and 180 seconds For details see Il C 4 b Harvest Timer S4 dip switch 1 amp 2 When the harvest timer terminates the harvest cycle is complete CB checks the position of F S and proceeds to the next cycle if itis closed or calls for a 1 minute fill if it is open The minimum total time allowed by CB for a complete harvest cycle is 2 minutes Diagnosis
21. store it in an approved container Do not discharge the refrigerant into the atmosphere 3 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing CAUTION 1 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 2 Always install a new drier every time the sealed refrigeration system is opened 3 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 4 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 5 Do not leave the system open for longer than 15 minutes when replacing or servicing parts 1 Refrigerant Recovery The icemaker is provided with refrigerant service valves Using proper refrigerant practices recover the refrigerant from the service valves and store it in an approved container Do not discharge the refrigerant into the atmosphere 43 2 Brazing A WARNING 1 R 4044 itself is not flammable at atmospheric pressure and temperatures up to 176 F 80 C
22. 56 V CES IAG ana KEE RE T TU m 57 A Cleaning and Sanitizing Instructions wazima 57 ei e KE EE 58 2 Sanitizing Procedure Following Cleaning 59 B ng ETT 60 C Preparing the Icemaker for Long Storage en 60 Important Safety Information Throughout this manual notices appear to bring your attention to situations which could result in death serious injury or damage to the unit AA WARNING Indicates a hazardous situation which could result in death or serious injury CAUTION Indicates a situation which could result in damage to the unit IMPORTANT Indicates important information about the use and care of the unit A WARNING This icemaker should be destined only to the use for which it has been expressly conceived Any other use should be considered improper and therefore dangerous The manufacturer cannot be held responsible for eventual damage caused by improper incorrect and unreasonable use To reduce the risk of death electric shock serious injury or fire follow basic precautions including the following Electrical connection must be hard wired and must meet national state and local electrical code requirements Failure to meet these code requirements could result in death electric shock serious injury fire or severe damage to equipment This unit requires an independent power supply See the nameplate for proper voltage and breaker fuse size Failure to use a proper brea
23. 910 Jet rfo o 2013 s Ws NOU fo 0 j o 0 AAA 7 ps TOME NM ZA ELLIIAYANSo9 uM 0140 MUM te 40 afr SE Y l TOUINOT 400 1 n TE 09 0 2 802 089 0 4010 114 25 C Performance Data 1 KM 2500SVVH3 water cooled APPROXIMATE ICE AMBIENT TEMP PRODUCTION PER 24 HR CFPC 70 21 80 27 90 32 Ibs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CONSUMPTION PER 24 HR 80 27 90 32 gal day m day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg em G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 35 500 BTU h AT 90 F 32 C WT 70 F 219C TOTAL HEAT OF REJECTION FROM COMPRESSOR 4900 BTU h AT 90 F 32 C WT 70 F 21 C PRESSURE DROP OF COOLINGWATERLINE lessthani0PSIG 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 26 2 KM 2500SRH3 remote air cooled APPROXIMATE ICE AMBIENT TEMP PRODUCTION PER 24 HR CFPC 70 21 80 27 90 32 Ibs day kg day 100 38 APPROXIMATE ELECTRIC 70 21 CONSUMPTION 80 27 90 32 watts 100 38 APPROXIMATE WATER 70 21 CON
24. Hoshizaki America Inc Stackable Crescent Cuber Models KM 2500SWH3 KM 2500SRH3 SERVICE MANUAL A Superior Degree of Reliability www hoshizaki com CYCLESAVER evercheck D a Number 73164 Issued 6 10 2010 IMPORTANT Only qualified service technicians should install service and maintain the icemaker No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual Failure to service and maintain the equipment in accordance with this manual may adversely affect safety performance component life and warranty coverage Hoshizaki provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker Should the reader have any questions or concerns which have not been satisfactorily addressed please call 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 Support 770 487 2331 Fax 1 800 843 1056 770 487 3360 E mail techsupport 9 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 IMPORTANT This manu
25. S 208 230 60 3 14 2 A 5 Min Freeze AT 104 F WT 80 F 30 A 30A TempCF 500 70 90 70 80 985 90 2395 1087 2365 1073 2184 991 100 2327 1055 2323 1054 2018 915 Crescent Cube 46 3 Ibs 21 kg 2160pcs N A 90 70 F 70 50 F 3720 3 78 3510 3 5 459 19 4 744 30 9 1430 101 1430 59 1 N A 48 x 27 3 8 x 36 7 16 1219 x 695 x 925 mm Stainless Steel Galvanized Steel Rear Net 390 Ibs 177 kg Shipping 415 Ibs 188 kg Permanent Connection Inlet 1 2 FPT Condenser Inlet 1 2 FPT Outlet 3 4 FPT Condenser Outlet 1 2 FPT 3 8 OD Tube Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model CS27K6E TF5 237 Water Cooled Tube in Tube Type Vertical type Stainless Steel and Copper Thermostatic Expansion Valve R404A 4 Ib 11 5 oz 21409 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 187 253 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice 2 KM 2500SRH3 remote air cooled AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR Ibs day kg day Refere
26. SUMPTION PER 24 HR 80 27 90 32 gal day m day 100 38 FREEZING CYCLE TIME 70 21 80 27 90 32 min 100 38 HARVEST CYCLE TIME 70 21 80 27 90 32 min 100 38 HEAD PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 SUCTION PRESSURE 70 21 80 27 90 32 PSIG kg cm G 100 38 TOTAL HEAT OF REJECTION FROM CONDENSER 40 600 BTU h AT 90 F 32 C WT 70 F 21 C TOTAL HEAT OF REJECTION FROM COMPRESSOR 5 600 BTU h AT 90 F 32 C WT 70 F 21 C CONDENSER VOLUME 441 CU IN URC 23F 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 27 IV Service Diagnosis A WARNING 1 This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death electric shock serious injury or fire 2 Risk of electric shock Use extreme caution and exercise safe electrical practices Moving parts e g fan blade can crush and cut Keep hands clear CHOKING HAZARD Ensure all components fasteners and thumbscrews are securely in place after the unit is serviced Make sure that none have fallen into the storage bin Make sure all food zones in the icemaker and storage bin are clean after the unit is serviced For cleaning procedures see VI Cleaning and Maintenance A Diagnostic Procedure The diagnostic procedure is basically
27. Sanitizing Instructions AA WARNING 1 Hoshizaki recommends cleaning this icemaker 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 4 Carefully follow any instructions provided with the bottles of cleaning and sanitizing solution 5 Never run the icemaker when the water tank is empty IMPORTANT 1 The cleaning valve is used to allow solution flow to the inside of the evaporator during the cleaning and sanitizing operation It should be closed for all icemaking operation The compressor will not operate unless this valve is completely closed 2 To open the cleaning valve the valve handle should be parallel to the valve body To close the valve the valve handle should be at a right angle to the valve body CLOSED POSITION OPEN POSITION 57 1 Cleaning Procedure 1 Dilute 38 fl oz 1 124 ml of recommended cleaner Hoshizaki Scale Away with 7 gal 26 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 back on after 3 minutes The harvest cycle starts and the cubes will be removed from the evaporator 3 Turn off the power supply 4 Remove the
28. TEST Button used to test relays on control board 0008840 OUTPUT EST a 2 C s a e O LJ 5 n m un e F TIMER 000000000 Be amp Freeze Timer LED BZ nm I a WHITE K3 Connector E301 ee Eu Harvest Control thermistor e H TIMER Harvest Backup RED K4 Connector Timer LED Open not connected e Alarm Buzzer e Microprocessor control board revision level indicated by last 2 digits on label Power OK LED red lights when power is supplied to the control board o BLACK Relay LEDs 4 indicate which relays BLACK K5 Connector Float Switch P N 2A1410 01 are energized as 2 2 listed belovv ES o em Part Number LED 2 X2 Relay 2 Nre K1 Ten Pin Connector Hot Gas Valve HGV s Z Wl E ste Fan Motor FM FM i Pins 1 through 10 off when LED on ES S 9 9 ete 1 9 Magnetic Contactor CR Ro ats Fan Motor Remote FMR LED 3 X3 Relay e 9 9 ais 2 Hot Gas Valve HGV Pump Motor PM E e M
29. VAC 5 or more If high voltage 147VAC 5 or more is present the icemaker automatically stops and the control board signals with 7 beeps every 3 seconds If low voltage 92VAC 5 or less is present the icmaker automatically stops and the control board signals with 6 beeps every 3 seconds When the proper supply voltage is resumed the icemaker automatically starts running again 17 3 LED Lights and Audible Alarm Safeties At startup a 5 second delay occurs while the control board conducts an internal timer check A beep occurs when power is turned off The red LED indicates proper control voltage and remains on unless a control voltage problem occurs The green LEDs 1 through 4 energize and sequence from startup as listed in the table below Note that the order of the LEDs from the outer edge of the control board is 1 4 3 2 For more information see II B Sequence of Operation 4 8 2 1 Minute Fill Cycle Harvest Cycle 1 4 2 Comp FMR 2 minutes 20 minutes 3 to 5 minutes WV HGV Freeze Cycle 1 Comp FMR 5 minutes freeze timer 30 to 35 minutes PM LLV setting Pump Out Cycle 1 4 Comp FMR 10 seconds 20 seconds pump out timer VVV PM setting HGV The built in safeties shut down the unit and have alarms as listed below No of Beeps 1 2 3 High Evaporator Temp Check for harvest problem stuck HGV or temperature gt 127 F relay hot water entering unit stuck HM or 53 C shorted thermis
30. VAC is not present CB is bad and must be replaced If 115VAC is present check PM continuity If PM is reversing but water does not pump out check and clean the check valve assembly and tubing If S4 dip switch 3 amp 4 are adjusted to 3 off and 4 on WV energizes 7 Normal Harvest Cycle same as the initial harvest cycle Return to IV A 4 Initial Harvest Cycle 8 Shutdown When the unit is running hold ice in contact with the thermostatic bulb the thermostatic BC switch opens within 10 seconds shutting down the unit The bin control is factory set and generally no adjustment is required However adjustment may be needed in some conditions particularly at higher altitude locations CAUTION Do not adjust S4 dip switch 7 out of the factory default position on this model This dip switch must be left in the factory default position or this unit will not operate correctly Diagnosis See IV C Bin Control Check Note Unit continues to cycle until bin control is satisfied or power is switched off The unit always restarts at the 1 minute fill cycle Legend BC bin control CB control board Comp compressor FMR fan motor remote F S float switch HGV hot gas valve HM headmaster C P R LLV liquid line valve PM pump motor TXV thermostatic expansion valve WV inlet water valve 30 B Control Board Check Before replacing a control board that does not show a visible defect and that you suspect is bad always con
31. a sequence check which can be used at unit startup or for system diagnosis This procedure allows you to diagnose electrical system and component failures in normal operating conditions of 70 F 21 C or warmer air and 50 F 10 C or warmer water temperatures Before conducting the diagnostic procedure check for correct installation proper voltage per unit nameplate and adequate water supply The maximum allowable voltage variation is x10 percent of the nameplate rating Check the dip switch settings to assure that S4 dip switch 3 4 7 8 9 amp 10 are in the factory default position S4 dip switch 1 2 5 amp 6 are cleaning adjustments and the settings are flexible For factory default settings see II C 4 a Default Dip Switch Settings Check CB using the steps in IV B Control Board Check As you go through the diagnostic procedure check to assure the components energize and de energize correctly If not those components or controls are suspect Always choose a white W neutral wire to establish a good neutral connection when checking high voltages 1 Turn off the power supply then access the control box Clear any ice from BC 2 Turn on the power supply then move the control switch to the ICE position A 5 second delay occurs The red POWER OK LED on CB comes on 3 1 Minute Fill Cycle LED 4 is on WV energizes After 1 minute CB checks for a closed F S If F S is closed harvest cycle begins If closed continue to
32. aks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 5 Disconnect the valve If replacing the hot gas valve also remove the strainer 10 Evacuate the system and charge it with refrigerant For water cooled model see the nameplate for the required refrigerant charge For remote air cooled model see the rating label inside the icemaker 11 Cut the leads of the solenoid allowing enough lead length to reconnect using closed end connectors 47 12 Connect the new solenoid leads 13 Attach the solenoid to the valve body and secure it with the bolt 14 Replace the panels in their correct positions 15 Turn on the power supply E Removal and Replacement of Evaporator CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 1 Turn off the power supply 2 Remove the panels and the front and top insulation 3 Recover the refrigerant and store it in an approved container 4 Re
33. al should be read carefully before the icemaker is serviced or maintenance operations are performed Only qualified service technicians should install service and maintain the icemaker Read the warnings contained in this booklet carefully as they give important information regarding safety Please retain this booklet for any further reference that may be necessary CONTENTS Important Sai YN EE 5 EE 6 Te 6 1 KM 2500SWHS water cooled 55 6 2 KM 2500SRH3 remote air cooled ica iru one R 7 B CGondenser IN 8 LE y ECTS 8 ll General Ia eidele E 10 nE OTI EE 10 1 KM 2500SVVH3 water coole 10 2 KM 2500SHH3 remote air cooled E 11 B SEQUENCES of Operation E 12 1 Sequence Cycles and Shutdown uncos atento teneas etn hose pia ENEE 12 a 1 Minute Fill Cycle 12 bania Harvest Cycle qe 12 Ne E 12 d PGI O YA m ee 12 6 Harvest Cycle M 13 RRE EE 13 2 Seg ence FloW CHAU 14 Re ee EE 15 1 Control Board Lay M 16 zo PML OS AA M 17 a Maximum Water Supply Period 6 minutes 17 b Harvest Backup Timer and Freeze Tmer mimi wima 17 c High Temperature E 17 d L w Watr Eeer 17 e High Voltage and Low Voltage Cut outs EE 17 3 LED Lights and Audible Ala
34. all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 1 Turn off the power supply 2 Remove the panels 3 Close the condenser water supply line shut off valve If connected to a closed loop water supply also close the condenser return outlet shut off valve 4 Open the condenser water supply line drain valve If connected to a closed loop water supply also open the condenser return outlet drain valve 5 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve 6 Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 7 Recover the refrigerant and store it in an approved container 8 Disconnect the condenser water inlet and outlet piping and the refrigeration inlet and outlet piping at the condenser 9 10 11 12 Remove the old condenser and install the new condenser Remove the drier then place the nevv drier in position Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG Use an electronic leak detector or
35. arvest 1 Check and replace applicable cycle 4 Abnormal Ice Possible Cause Remedy 1 Small cubes a Pump Out Check Valve 1 Dirty or worn and 1 Clean or replace leaking by b Ice Cube Guide 1 Out of position 1 Place in position Circulated water falls into bin c Water System 1 Water supply line too 1 Increase water line size small requires 3 8 OD line dedicated per machine 2 Water filter clogged or 2 Replace filter or install a flow rate too small higher flow rate filter d Inlet Water Valve 1 Dirty mesh filter or 1 Clean orifice e Pump Motor 1 RPM too slow 1 See chart 1 5 f Control Board 1 Defective 1 See IV B Control Board Check 41 2 Cloudy or irregular a Evaporator 1 Frozen up 1 See IV F 2 Evaporator is cubes Frozen Up 3 Damaged 3 Replace b Water System 1 Water supply line too 11 Increase water line size small requires 1 2 nominal line dedicated per machine 2 Water filter clogged or 2 Replace filter or install a flow rate too small higher flow rate filter 3 High hardness or 3 Install a water softener or contains impurities filter c Spray Guide 1 Clean 5 Other Possible Cause 1 lcemaker will not stop a Bin Control Thermostat 1 Set too cold 1 See ID Bin Control 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
36. ct black F S connector from CB BLACK K5 connector If the unit switches out of freeze with F S removed but would previously not switch out of freeze with F S connected long freeze 3 beep alarm F S may be sticking To check and clean F S see IV D Float Switch Check and Cleaning If the unit remains in freeze with F S removed CB is bad and must be replaced See V O Removal and Replacement of Control Board Note Normal freeze cycle will last 20 to 40 minutes depending on model and conditions Cycle times and refrigerant pressures should follow performance data provided in this manual See III C Performance Data 29 6 Pump Out Cycle 10 20 second pump out LEDs 1 3 and 2 are on LED 4 is on when S4 dip switch 3 amp 4 are set to 3 off and 4 on Comp and FMR remain energized HGV energizes WV energizes if S4 dip switch 3 off amp 4 on LLV de energizes PM stops for 2 seconds then reverses for 10 20 seconds depending on pump out timer S4 dip switch 3 amp 4 setting When pump out timer terminates the pump out is complete The pump out frequency control is factory set for every cycle The first pump out occurs after the 1st freeze cycle and every cycle thereafter Generally no adjustment is required For details see 11 4 4 Pump Out Frequency Control S4 dip switch 5 amp 6 Diagnosis If PM does not reverse check PM circuit and capacitor Next check CB 10 pin connector 5 pin dark blue DBU wire for 115VAC If 115
37. d Remote Condenser Unit URC 23F Vertical type Stainless Steel and Copper Thermostatic Expansion Valve Condensing Pressure Regulator on Icemaker 190 PSI R404A 24 Ib 7 5 oz 11100g Icemaker 14 Ibs 12 3 oz Cond Unit 9 Ibs 11 2 oz 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 Remote Condenser Unit VOLTAGE RANGE 187 253 V AMBIENT TEMP 45 100 F WATER SUPPLY TEMP 45 90 F WATER SUPPLY PRESSURE 10 113 PSIG Note We reserve the right to make changes in specifications and design without prior notice B Condenser Unit 1 URC 23F uu 1205 A 47 7716 5 1120 2 4 4 17167 eb E Jee les l als 5 Mw ni ROGA e p 2 5 48 1 167 Kq o SR LO ea RE b i ooj Hu bol x j i R TANE E a Y 11 MEUM 75 444 2 15 16 1121727227 Note We reserve the right to make changes in specifications and design without prior notice SPECIFICATIONS MODEL URC 23F AC SUPPLY VOLTAGE FAN MOTOR EXTERIOR DIMENSIONS WxDxH DIMENSIONS INCLUDING LEGS WxDxH EXTERIOR FINISH WEIGHT CONNECTIONS ELECTRIC REFRIGERANT CONDENSER FAN MOTOR PROTECTION REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE OPERATING CONDITIONS ACCESSORIES SUPPLIED
38. del CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the headmaster and drier by using wet cloths to prevent the headmaster and drier from overheating Do not allow the drier to exceed 250 F 121 C 1 Turn off the power supply 2 Remove the panels from the remote condenser unit 3 Recover the refrigerant and store it in an approved container 4 Before heating break off the stub on the dome to release the dome charge 5 Disconnect the headmaster 6 Place the new headmaster in position 7 Remove the drier then place the new drier in position 52 8 Braze all fittings with nitrogen gas flowing at a pressure of 3 to 4 PSIG 9 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 10 Evacuate the system and charge it with refrigerant See the rating label inside the icemaker for the required refrigerant charge 11 Replace the panels in their correct positions 12 Turn on the power supply K Removal and Replacement of Thermistor This s
39. drain At the same time water flows through the small float switch tube to power flush the float switch 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 set and generally no adjustment is required However where water quality is bad and the icemaker needs a longer pump out time the pump out timer can be adjusted The pump out timer control can be set to pump out for 10 or 20 seconds 4 Dip Switch Setting Time seconds Inlet wea OFF 10 00 Water Valve a f open Wes 1 10 10 T1 Time to drain the water tank T2 Harvest timer at pump out d Pump Out Frequency Control S4 dip switch 5 amp 6 The pump out frequency control is factory set to drain the water tank every cycle and generally no adjustment is required The pump out frequency control can be set to have a pump out occur every cycle or every 2 5 or 10 cycles The first pump out occurs after the 1st freeze cycle 4 Dip Switch Setting Frequency Woe No 5 FF 20 e Bin Control Selector S4 dip switch 7 S4 dip switch 7 is the bin control selector CAUTION Do not adjust This dip switch must be left in the factory default position or this unit will not operate correctly Factory set for proper operation Do not adjust When set to the on position on a unit with a t
40. duct the following check procedure This procedure will help you verify your diagnosis Alarm Reset If the control board is in alarm beeping press the ALARM RESET button on the control board with power on Once reset the unit starts at the 1 minute fill cycle For audible alarm information see II C 3 LED Lights and Audible Alarm Safeties 1 Check the dip switch settings to assure that S4 dip switch 3 4 7 8 9 amp 10 are in the factory default position S4 dip switch 1 2 5 amp 6 are cleaning adjustments and the settings are flexible For factory default settings see II C 4 a Default Dip Switch Settings 2 Move the control switch to the ICE position If the red POWER OK LED is on control voltage is good If the POWER OK LED is off check the control transformer secondary circuit The control transformer secondary circuit includes the cleaning valve interlock switch Make sure the interlock switch is closed otherwise no control voltage is supplied to the K2 connector Transformer output is 10 5V at 115V primary input If the secondary circuit has proper voltage and the red LED is off the control board is bad and should be replaced See V O Removal and Replacement of Control Board If the secondary circuit does not have proper voltage check the control transformer primary circuit Check for 115V at the control board K1 ten pin connector Check the 10 pin BR wire to a white neutral wire for 115V Always choos
41. e 4 Defective capacitor 4 Replace 5 Fan blade bound 5 Check and replace 7 Fan motor will b Control Board 1 Defective 1 See IV B Control Board not start or is not Check operating except water cooled model continued 8 All components a Refrigerant 1 Low charge 1 Check for leaks Recover run but no ice is repair evacuate and produced recharge 2 Air or moisture 2 Replace drier evacuate trapped and recharge b Compressor 1 Defective 1 Replace c Hot Gas Valve 1 Continues to open in 1 Check and replace freeze cycle d Liquid Line Valve 1 Continues to close in 1 Check and replace if applicable freeze cycle e Inlet Water Valve 1 Inlet water valve is 1 Check for water leaks with wide open during icemaker off freeze f Expansion Valve 1 Bulb loose 1 Secure bulb 2 Operating erratically 2 Check and replace g Headmaster C P R 1 Not operating properly 1 Replace headmaster remote air cooled and liquid line model temperature too warm h Water Supply Line Condenser water 1 Check and get water cooled model pressure too low or recommended pressure off and high pressure control opens and closes frequently i Water Regulating Valve 1 Set too high 1 Adjust or replace See water cooled model V I Adjustment of Water Regulating Valve 2 Evaporator is Frozen Up Possible Cause 1 Freeze cycle time is a Inlet Water Valve 1 Diaph
42. e a white neutral wire to establish a good neutral connection when checking voltages For additional checks see IV F 1 1 The icemaker will not start 3 The OUTPUT TEST button provides a relay sequence test Make sure the control switch is in the ICE position then press the OUTPUT TEST button The correct lighting sequence is none 2 3 4 1 Note that the order of the LEDs from the outer edge of the control board is 1 4 3 2 Components e g compressor cycle during the test Following the test the icemaker resumes operation If the LEDs do not light as described above the control board is bad and should be replaced See VO Removal and Replacement of Control Board 4 To verify voltage output from the control board to the components slide the control board K1 ten pin connector out far enough to allow multimeter lead contact With the unit in the cycle to be tested check output voltage from the corresponding pin on the control board K1 ten pin connector to ground If output voltage is not found and the appropriate LED is on the control board is bad and should be replaced See V O Removal and Replacement of Control Board 31 C Bin Control Check To check the thermostatic bin control follow the steps below CAUTION When the 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 icemak
43. eads With the water tank full the float switch should be closed If the float switch is closed and the icemaker will not switch from the 1 minute fill cycle to the initial harvest cycle replace the control board If the float switch is open confirm that the water tank is full If the tank is not full check the water supply water filters and inlet water valve If the tank is full follow the steps in IV D 2 Float Switch Cleaning After cleaning the float switch check it again Replace if necessary 2 Float Switch Cleaning Depending on local water conditions scale may build up on the float switch Scale on the switch can cause the float to stick In this case the float switch should be cleaned 1 Turn off the power supply 2 Remove the front panel and move the control switch to the OFF position 3 Remove the insulation panel then remove the cap located on the front bottom part of the ice dropping hole Drain the water tank T Vent 4 Replace the cap in its correct position Be m careful not to cross thread it Flush 5 Disconnect the vent tube and the flush tube from the top of the float switch then remove the float switch assembly from the mounting bracket and remove the rubber boot from the bottom of the float switch Shaft Float Switch assembly See Fig 2 E Housing 6 Remove the retainer rod from the bottom of the float switch assembly then remove the Float float
44. ection covers removal and replacement of the thermistor For a thermistor check procedure see IV E Thermistor Check CAUTION 1 The thermistor is fragile handle very carefully 2 Always use the 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 the recommended foam insulation non absorbent type or equivalent 4 Do not shorten or cut the thermistor leads 1 Turn off the power supply 2 Remove the panels 4 Disconnect the white thermistor connector from the control board WHITE K3 connector 5 Remove the plastic cable ties foam insulation thermistor holder and thermistor See Fig 4 6 Scrape away the old sealant on the thermistor holder and the suction pipe 3 Remove the control box cover Thermistor Lead Cable Tie 71 l 7 VVipe off moisture or condensation on the AY 2 n suction pipe 7 2 Ge G 7 UNI 8 Smoothly apply recommended sealant KE4560RTV Part Code 60Y000 11 or 4A0683 01 to the thermistor holder L L 11 booed rzi NY concave 9 Attach the new thermistor to the suction Foam Insulation Thermistor Holder pipe in the same position as the previous thermistor Be very careful to prevent Fig 4 damage to the leads Secure it using the thermistor holder and recommended foam insulation 53 10 Secure the insu
45. enters the tank and closes F S This serves as a low water safety to protect PM b Initial Harvest Cycle LEDs 1 4 and 2 are on WV remains energized Comp FMR and HGV energize CB monitors the warming of the evaporator via the thermistor located on the suction line When the thermistor warms to 48 F 9 C CB reads a 3 9 kO signal from the thermistor and turns harvest termination over to the harvest timer S4 dip switch 1 amp 2 which is factory set for normal conditions The harvest timer has settings of 60 90 120 and 180 seconds For details see Il C 4 b Harvest Timer S4 Dip Switch 1 amp 2 When the harvest timer terminates the harvest cycle is complete At the end of harvest CB checks the position of F S and proceeds to the next cycle if it is closed or calls for a 1 minute fill cycle if it is open The minimum total time allowed by CB for a complete harvest cycle is 2 minutes WV is energized during harvest for a maximum of 6 minutes or the length of harvest whichever is shorter c Freeze Cycle LED 1 is on Comp and FMR remain energized PM and LLV energize HGV and WV de energize For the first 5 minutes CB will not accept a signal from F S This 5 minute minimum freeze time is short cycle protection for Comp At the end of 5 minutes F S assumes control of freeze termination As ice builds on the evaporator the water level in the tank lowers The freeze cycle continues until F S opens then CB terminates the freeze cycle
46. er operates continuously even if the ice storage bin is filled with ice Setting in the prohibited range may result in severe damage to the icemaker The thermostatic bin control is factory set and generally no adjustment is required However adjustment may be needed in some conditions particularly at higher altitude locations Adjust it if necessary so that the icemaker stops automatically within 10 seconds after ice contacts the bin control 1 Turn off the power supply 2 Remove the front panel then remove the control box cover 3 4 Clear any ice away from the thermostatic bulb then hold your hand around the thermostatic bulb to warm it up 5 Check for continuity across the thermostatic bin control switch If closed continue to step 6 If open adjust or replace the thermostatic bin control 6 With the multimeter test leads still in place hold ice on the thermostatic bulb to lower the temperature Within 10 seconds the thermostatic bin control switch should open no continuity If it remains closed adjust or replace the thermostatic bin control Disconnect the thermostatic bin control wires from the thermostatic bin control switch D Float Switch Check and Cleaning 1 Float Switch Check To check the float switch follow the steps below 1 Turn off the power supply 2 Remove the front panel Move the control switch to the OFF position then remove the insulation panel 3 Remove the drain plug located
47. he level of ice in the bin It is in line with the power supply to the control switch The thermostatic bin control switch shuts down the unit within 10 seconds when ice contacts the thermostatic bulb regardless of the cycle at activation The bin control is factory set and generally no adjustment is required However adjustment may be needed in some conditions particularly at higher altitude locations For further details see IV C Bin Control Check E Float Switch The float switch is used to determine that there is sufficient water in the tank after the 1 minute fill cycle and after each harvest cycle The float switch is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle No adjustment is required F Thermistor The thermistor is used as a harvest control sensor The thermistor s resistance varies depending on the suction line temperature The control board monitors the resistance to start the harvest timer No adjustment is required G Control Switch The control switch has three positions OFF for power off ICE for icemaking and WASH to activate the water pump when cleaning and sanitizing 22 Ill Technical Information A Water Circuit and Refrigeration Circuit 1 KM 2500SVVH3 water cooled UO JAM Wm n sl uonejeBujeu YOUMS Go G jno dung 92994 S A BA yo uo 4 urens YOUMS aunsseld UBIH
48. he 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 reaches 127 7 F 53 4 C the control board reads a 8 kO signal from the thermistor and shuts down the icemaker The control board signals with 1 beep every 3 seconds To reset this safety press the ALARM RESET button on the control board with power on d Low Water Safety The control board checks the position of the float switch at the end of the initial 1 minute 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 proceeds to the next cycle If the float switch is in the down position electrical circuit open the control board returns to the 1 minute fill cycle until water enters the tank and the float switch closes Once the float switch closes the control board proceeds to the next cycle The unit should not start without adequate water in the tank This serves as a low water safety to protect the pump motor from mechanical seal failure For water cooled model if the water is shut off the unit is protected by the high pressure switch e High Voltage and Low Voltage Cut outs The maximum and minimum allowable supply voltages of this unit are limited by the high voltage and low voltage cut outs Miswiring especially on single phase 3 wire models may cause excessive voltage 147
49. hermostatic bin control a 5 beep alarm sounds open circuit and the unit does not operate 4 Di itch Setti eB Pee en Bin Control OFF f Factory Use S4 dip switch 8 Factory set for proper operation Do not adjust This must be left in the factory default position g Freeze Timer S4 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 the freeze timer the control board initiates the harvest cycle After 2 consecutive timer terminations the control board shuts down the icemaker In this case see IV F 3 Low Ice Production for possible solutions The freeze timer is factory set and generally no adjustment is required Before changing this setting contact Hoshizaki Technical Support at 1 800 233 1940 for recommendations S4 Dip Switch Setting Time minutes 21 D Bin Control CAUTION When the ambient temperature is below 45 F 7 C the thermostatic bin control switch opens and shuts down 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 may result in severe damage to the icemaker The thermostatic bin control switch is a temperature controlled switch used to control t
50. hold down bolts washers and rubber grommets 6 Remove the discharge and suction pipes 7 Remove the compressor Unpack the new compressor package 8 Attach the rubber grommets of the prior compressor 9 Place the compressor in position and secure it using the bolts and washers 45 10 11 12 13 Remove the drier then place the new drier in position Remove the plugs from the suction discharge and process pipes Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 14 Evacuate the system and charge it with refrigerant For water cooled model 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 On remote air cooled model connect the crankcase heater 16 Replace the panels in their correct positions 17 Turn on the power supply C Removal and Replacement of Expansion Valve CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after all other repair or replacement
51. inse thoroughly Note If you do not sanitize the icemaker go to step 9 in 2 Sanitizing Procedure 2 Sanitizing Procedure Following Cleaning Procedure 1 Dilute 3 5 fl oz 104 ml or 7 tbs of a 5 25 sodium hypochlorite solution chlorine bleach with 7 gal 26 1 of warm water 2 Pour the sanitizing solution into the water tank 3 Replace the insulation panel and the front panel in their correct positions Note Make sure that the control switch is in the WASH position and the cleaning valve is open 4 5 6 7 Turn on the power supply to start the sanitizing process Turn off the power supply after 15 minutes Remove the front panel and the insulation panel Remove the cap located on the front bottom part of the ice dropping hole Drain the water tank Replace the cap and the insulation panel in their correct positions 8 9 10 11 12 13 Repeat steps 16 through 27 in 1 Cleaning Procedure two times to rinse thoroughly Close the cleaning valve Move the control svvitch to the ICE position Replace the front panel in its correct position Clean the storage bin using a neutral cleaner Rinse thoroughly after cleaning Turn on the power supply to start the automatic icemaking process 59 B Maintenance IMPORTANT This icemaker must be maintained individually referring to the instruction manual and labels provided with the icemaker 1 Stainless
52. ker or fuse can result in a tripped breaker blown fuse or damage to existing wiring This could lead to heat generation or fire THIS UNIT MUST BE GROUNDED Failure to properly ground this unit could result in death or serious injury This unit should be disassembled or repaired only by qualified service personnel to reduce the risk of electric shock injury or fire Do not make any alterations to the unit Alterations could result in electric shock injury fire or damage to the unit L Specifications A Icemaker 1 KM 2500SVVH3 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 100 165 WATER gal 24HR gal 100 Ibs WATER COOLED CONDENSER gal 24HR gal 100 Ibs CEC CEE TIER LEVEL ENERGY STAR 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 CONDITION
53. lation using the plastic cable ties 11 Connect the white thermistor connector through the bushing of the control box to the control board WHITE K3 connector CAUTION Do not shorten or cut the thermistor leads 12 Replace the control box cover and the panels in their correct positions 13 Turn on the power supply L Removal and Replacement of Fan Motor Remote Air Cooled Model Note When replacing a fan motor it is recommended that a new capacitor be installed 1 Turn off the power supply 2 Remove the remote condenser unit panels 3 Remove the junction box cover from the remote condenser unit 4 Disconnect the fan motor wires 5 Remove the fan motor bracket and fan motor 6 Install the new fan motor connect the fan motor wires and replace the removed parts in the reverse order of which they were removed 7 Replace the junction box cover in its correct position 8 Replace the panels in their correct positions 9 Turn on the power supply M Removal and Replacement of Inlet Water Valve 1 Turn off the power supply 2 Close the icemaker water supply line shut off valve Open the icemaker water supply line drain valve 3 4 5 6 7 8 Remove the front panel Disconnect the valve outlet tubing by releasing the clamp Loosen the fitting nut Be careful not to lose the washer Disconnect the terminals from the inlet water valve Remove the bracket and valve from the unit wa ee a a Install the
54. move the condenser 7 Remove the shroud from the condenser and attach to the new condenser 8 Install the new condenser 9 Remove the drier located in the icemaker then place the new drier in position 10 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 11 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 12 Evacuate the system and charge it with refrigerant See the rating label inside the icemaker for the required refrigerant charge 13 Replace the removed parts in the reverse order of which they were removed 14 Replace the panels in their correct positions 15 Turn on the power supply 50 H Removal and Replacement of Water Regulating Valve water cooled model CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 1 Turn off the power supply 2 Remove the panels 3 Close the condense
55. move the spray tubes Remove the insulation at the notch where the refrigeration tubing passes through the molded chassis 5 Disconnect the evaporator tubing Note The pipes in the evaporator case are specially coated to resist corrosion Use sandpaper to remove the coating from the brazing connections before unbrazing 6 Remove the pop rivets securing the evaporator then lift out the evaporator 7 Install the new evaporator 8 Remove the drier then place the new drier in position 9 Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG 10 Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 11 Evacuate the system and charge it with refrigerant For water cooled model see the nameplate for the required refrigerant charge For remote air cooled model 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 48 F Removal and Replacement of Water Cooled Condenser CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after
56. nce without marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC amp WATER CONSUMPTION ELECTRIC W KWH 100 165 WATER gal 24HR gal 100 Ibs CEC CEE TIER LEVEL ENERGY STAR 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 208 230 60 3 17 7 A 5 Min Freeze AT 104 F WT 80 F 30A 30A Ambient WATER TEMP F Temp F 5980 70 2424 1100 2373 1076 2196 996 80 2385 1082 2306 1046 2069 939 90 2373 1076 2250 1021 2035 923 100 2301 1044 2200 998 1837 833 Crescent Cube 46 1 Ibs 20 9 kg 2160pcs N A 90 70 F 70 50 F 4220 4 5 3780 3 7 419 18 6 791 32 6 2 YES 48 x 27 3 8 x 36 7 16 1219 x 695 x 925 mm Stainless Steel Galvanized Steel Rear Net 390 Ibs 177 kg Shipping 440 Ibs 200 kg Permanent Connection Inlet 1 2 FPT Outlet 3 4 FPT 3 8 OD Tube Float Switch Hot Gas and Water Thermistor and Timer Timer Controlled Overflow Pipe N A Thermostat Hermetic Model MTZ 57 HL3A Air Coole
57. new valve Replace the removed parts in the reverse order of which they were removed Make sure the washer is in place in the fitting nut 54 9 Close the icemaker water supply line drain valve Open the icemaker water supply line shut off valve 10 Turn on the power supply 11 Check for leaks 12 Replace the front panel in its correct position N Removal and Replacement of Pump Motor 1 Turn off the power supply 2 Remove the front panel 3 Drain the water tank by removing the cap located on the front bottom part of the ice dropping hole See Fig 5 4 Replace the cap in its correct position Be careful not to cross thread the cap Inside rios RE Dropping Hole 8 Remove the pump housing and check the impeller 5 Disconnect the pump suction and discharge hoses 6 Remove the closed end connectors from the pump motor leads 7 Remove the two screws and the pump motor bracket id NY Fig 5 9 10 Install the new motor or new parts and replace the removed parts in the reverse order of which they were removed If the impeller is defective install a new impeller 11 Turn on the power supply and check for leaks 12 Replace the front panel in its correct position 55 O Removal and Replacement of Control Board CAUTION 1 The control board is fragile handle very carefully 2 The control board contains integrated circuits which are susceptible to failure due to static discharge
58. nnector to the control board WHITE K3 connector 9 Replace the control box cover in its correct position then turn on the power supply 10 Move the control switch to the ICE position 11 Once the harvest cycle starts begin timing the harvest cycle 12 The harvest timer should expire and terminate the harvest cycle within 2 to 3 minutes If the harvest timer does not expire and terminate the harvest cycle the harvest timer is bad and the control board should be replaced See V O Removal and Replacement of Control Board 3 Remove the control box cover 34 F Diagnostic Charts 1 No Ice Production 1 The icemaker will not a Power Supply 1 Off blown fuse or 1 Turn on replace or reset tripped breaker 3 Bad contacts 3 Check for continuity and replace 4 Not within 4 Refer to nameplate and specifications correct b Transformer main 1 Voltage tap switch 1 Verify incoming voltage transformer does not match move switch to proper incoming voltage setting 2 Coil winding open or 12 Replace shorted c Water Supply 1 Water supply off or 1 Check and get pressure too low recommended pressure 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 IV C Bin Control Check 4 Bulb out of position 4 Place in position 5 Bad contacts 5 Check for continui
59. ol Thermostat Bracket 2 KM 2500SRH3 remote air cooled D c o d 3 Q x E o gt 22 85 2 do x oO o faal 5 m gt o S E 9 e c gt o m om S 5 969 tc Se ss 8 5 5 8 bc 98 E 2 2 o Z Z S sa 38 82 8 6 c 2 oO e 90 Zu o o d S 5 T 0 IQ u O fC m n 3 g zm gt o i 3 3 Ka N S g5 179 2 t 2 ge f N 3 di E 9 gt 0 tu x D G 2 3 SE E ce 3 E E 6 8 E e s 2 g a 2 8 DN IR 2 X IS Sy o Li RY c NN NS n ei AY d h s Spray Tubes Compressor Cleaning Valve Float Switch Evaporator Assembly Check Valve water Water Pump Control Switch Bin Control Thermostat Bracket Bin Control Bulb Holder Bin Control Z Bracket Bin Control Extension Bracket 11 B Sequence of Operation 1 Sequence Cycles and Shutdown The steps in the sequence are as outlined below When power is supplied and BC is closed CB red POWER OK LED comes on There is a 5 second delay before startup Note that the order of the LEDs from the outer edge of CB is 1 4 3 2 a 1 Minute Fill Cycle LED 4 is on WV energizes and the 1 minute fill cycle begins After 1 minute CB checks for a closed F S If F S is closed the harvest cycle begins If not WV remains energized through additional 1 minute fill cycles until water
60. on the lower front part of the ice dropping hole Allow the water tank to drain See Fig 1 Inside of Ice Front e Dropping Hole 4 Replace the drain plug in its correct position Be careful not to cross thread it SS 5 Remove the control box cover Cap Fig 1 6 Disconnect the black float switch connector from the control board BLACK K5 connector 7 Check for continuity across the float switch leads With the water tank empty the float switch should be open If open continue to step 8 If closed follow the steps in IV D 2 Float Switch Cleaning After cleaning the float switch check it again Replace if necessary 32 8 Reconnect the black float switch connector then replace the control box cover in its correct position 9 Move the control switch to the ICE position Replace the insulation panel and the front panel in their correct positions then turn on the power supply After 1 minute the 1 minute fill cycle should end and the initial harvest cycle should begin If the initial harvest cycle begins the float switch is good and the check is complete If the initial harvest cycle does not begin continue to step 10 10 Turn off the power supply 11 Remove the front panel 12 Move the control switch to the OFF position 13 Remove the control box cover 14 Disconnect the black float switch connector from the control board BLACK K5 connector 15 Check for continuity across the float switch l
61. particularly at higher altitude locations CAUTION Do not adjust S4 dip switch 7 out of the factory default position on this model This dip switch must be left in the factory default position or this unit will not operate correctly Legend BC bin control CB control board Comp compressor FMR fan motor remote F S float switch HGV hot gas valve LLV liquid line valve PM pump motor WV inlet water valve uonisod 39l eui ui peoejd si YIJIMS 000 y U UM JOU WM PUN eui ejejduaoo ae Burzniues pue Buiueejo Jaye sajen Burueejo y SOLO eyoN iquu sse ajejd soyesodend v Jo episui BY pue episino eui y 0q 1940 MO Jeziues pue Jeueejo eui uedo A PA Buiueejo eui Ajquiesse ajejd 1oye10de o QU Jo episino eui 1 AO MOJ 211485 pue Jeueej eu pasojo eA eA Duiueejo eui uy ojowu duind eui o p liddns 51 amod uonisod HSVM 24 ui ueuM YUN y Burzniues pue Buiuee o ueuw pesn S yms o41u09 y uo UOHISOd HSVM uonisod HSVM au l S U9IIMS 104002 ay uauM pezibJeu3 sjueuoduio NLA O UI AM JO4JUOD ulq onejsouueui 38g L Jojow duind Nd p nb l AT1 HAIBA 586 104 YOUMS 180J S 4 Josseidwoo dwiog pu B q peziB1eue ep sjueuoduuoo u do 291 peso 9g enoqe OL ak IA ANUN Ls ye sugs iyewa ging oneisouueuj Suluono 991 ON
62. quired refrigerant charge 16 Connect the flare connections 17 Close the drain valve s Open the condenser water supply line shut off valve If connected to a closed loop water supply also open the condenser return outlet shut off valve 51 18 Check for water leaks 19 Replace the panels in their correct positions 20 Turn on the power supply Adjustment of Water Regulating Valve Water Cooled Model 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 Adjustment Screw CW Lower CCW Higher 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 Top View in the proper range See Fig 3 Next check that the reference pressure is in the range indicated in the Head Pressure table in Fig 3 the Performance Data section See III C Performance Data If it is not in the proper range verify the refrigerant charge 3 Check that the condenser drain temperature is stable J Removal and Replacement of Headmaster Condensing Pressure Regulator C P R Remote Air Cooled Mo
63. r 1 See chart 1 3 k Condenser Water 1 Water regulating valve 1 Adjust or replace See water cooled model set too high V I Adjustment of Water Regulating Valve 2 Condenser water 2 Check and get pressure too low recommended pressure 3 Water temperature out 3 Correct to specification of specification 1 Liquid Line Valve 1 Erratic sticking 1 Check and replace m Headmaster C P R 11 Bypassing 1 Replace remote air cooled model n Control Board 1 Float switch 1 Check and reconnect connection loose K5 2 Defective 2 See IV B Control Board Check 40 Problem Possible Cause 2 Harvest cycle time is a Water Supply 1 Water temperature too 1 Increase temperature long cold b Thermistor 1 Out of position or 1 Reattatch and secure See defective IV E Thermistor Check c Control Board 1 Not reading 1 Check and replace thermistor 2 Sending voltage to 2 Check and replace See liquid line valve if IV B Control Board applicable in harvest Check d Inlet Water Valve 1 Clogged 1 Clean or replace fe Evaporator i Scaled up f Hot Gas Valve 1 Does not open or 1 Check and replace opens partially g Expansion Valve 1 Wide open in harvest 1 Check and replace h Water Regulating Valve 1 Open during harvest 1 Adjust or replace See water cooled model V I Adjustment of Water Regulating Valve i Liquid Line Valve if 1 Open during h
64. r water supply line shut off valve If connected to a closed loop water supply also close the condenser return outlet shut off valve 4 Open the condenser water supply line drain valve If connected to a closed loop water supply also open the condenser return outlet drain valve 5 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve 6 Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 7 8 9 10 Recover the refrigerant and store it in an approved container Disconnect the capillary tube at the condenser outlet Disconnect the flare connections of the valve Remove the screws and the valve from the bracket Install the new valve 12 13 14 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 N Use an electronic leak detector or soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 15 Evacuate the system and charge it with refrigerant See the nameplate for the re
65. ractionation Place the service cylinder on the scales if the service cylinder is not equipped with a dip tube invert the service cylinder then place it on the scales Open the high side valve on the gauge 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 CAUTION To prevent compressor damage use a throttling valve or liquid dispensing device to add the remaining liquid charge through the low side service valve with the unit running 9 Close the service valves then close the gauge manifold valves and disconnect the hoses 10 Cap the service valves to prevent a possible leak B Removal and Replacement of Compressor CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 1 Turn off the power supply 2 3 4 Remove the terminal cover on the compressor and disconnect the compressor wiring On remote air cooled model disconnect the crankcase heater Remove the panels Recover the refrigerant and store it in an approved container 5 Remove the
66. ragm does not 1 Check for water leaks with too long close icemaker off b Float Switch 1 Float does not move 11 Clean or replace freely 2 Defective switch 2 Check and replace c Evaporator 1 Scaled up 2 Damaged 2 Replace d Spray Tubes disconnected IV E Thermistor Check 9 Refrigerant Charge 1 Low Charge 1 Check for leaks Recover repair evacuate and recharge 38 Possible Cause 1 Freeze cycle time is h Expansion Valve 1 Bulb loose 1 Secure bulb too long continued 2 Operating erratically 12 Check and replace Control Board 1 Defective 1 See IV B Control Board Check 2 All ice formed on a Evaporator 1 Scaled up evaporator does not 2 Damaged 2 eee fall into bin in harvest cycle b Ambient and or Water 1 Too cool 1 Increase temperature Water Supply Line 1 Water pressure too 1 Check and get low recommended pressure Water System 1 Water supply line too 1 Increase water line size small requires 3 8 OD line dedicated per machine 2 Water filter clogged or 2 Replace filter or install a flow rate too small higher flow rate filter e Inlet Water Valve 1 Dirty mesh filter or 1 Clean orifice 2 Diaphragm does not 12 Check for water leaks with close icemaker off 0 Spray Tubes disconnected V E Thermistor Check 2 BCS does not 2 move 3 Wiring to hot gas 3 Check for loose valve connection or open and
67. rain valve If connected to a closed loop water supply also open the condenser return line drain valve 4 Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve 5 Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring While holding the valve open blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out 6 Close the drain valve s then replace the right side panel and front panel in their correct positions 61
68. ravity 4 Attach a compressed air or carbon dioxide supply to the icemaker water supply line drain valve 5 Make sure at least 3 minutes have elapsed since you turned off the power supply Make sure the control switch is in the ICE position Replace the front panel in its correct position and turn on the power supply 6 Blow the icemaker water supply line out using the compressed air or carbon dioxide supply 7 Close the icemaker water supply line drain valve 60 2 Drain the water tank 1 Turn off the power supply then remove the front panel Move the control switch to the OFF position 2 Remove the insulation panel Remove the cap located on the front bottom part of the ice dropping hole Drain the water tank See Fig 7 3 Replace the cap and the insulation panel in their correct positions Be careful not to cross thread the cap 4 Replace the front panel in its correct position 5 Remove all ice from the storage bin Clean the storage bin using a neutral cleaner Rinse thoroughly after cleaning Inside of Ice Dropping Hole Fig 7 3 On water cooled model only first remove the water from the water cooled condenser 1 Make sure the power supply is off then remove the front panel and right side panel 2 Close the condenser water supply line shut off valve If connected to a closed loop water supply also close the condenser return line shut off valve 3 Open the condenser water supply line d
69. replace i Expansion Valve 1 Check and replace Liquid Line Valve 1 Continues to open in 1 Check operation in harvest if applicable harvest cycle cycle and replace Control Board 1 Harvest timer is set 1 Adjust longer referring to too short Il C 4 b Harvest Timer S4 dip switch 1 amp 2 2 Defective 2 See IV B Control Board Check l Refrigerant Charge 1 Low Charge 1 Check for leaks Recover repair evacuate and recharge m Water Regulating Valve 1 Leaking by in harvest 1 Check and replace water cooled model 39 Possible Cause 3 Other 8 Ice Cube Guide 1 Out of position 1 Place in position b Bin Control Thermostat 1 Bulb out of position 1 Place in position 2 Bad contacts 2 Check for continuity and replace 3 Low Ice Production Problem Possible Cause 1 Freeze cycle time is a Inlet Water Valve 1 Diaphragm does not 11 Check for water leaks with long close icemaker off b Float Switch 1 Float switch does not 11 Clean or replace move freely 0 Spray Tubes WAA a f Condenser except 1 Air filter or condenser 1 Clean water cooled model clogged except water cooled model 9 Refrigerant Charge 1 Low charge 1 Check for leaks Recover repair evacuate and recharge h Hot Gas Valve 1 Check and replace i Expansion Valve 1 Bulb loose 1 Secure bulb 2 Operating erratically 2 Check and replace j Compresso
70. rifice 1 Clean gets clogged and water supply cycle does not finish 2 Coil winding open 2 Replace 3 Wiring to inlet water 13 Check for loose valve connection or open and replace n Float Switch 1 Bad contacts 1 Check for continuity and replace 2 Float does not move 2 Clean or replace freely 0 Control Board 1 Defective or in alarm 1 See IV B Control Board Check 2 Fill cycle will not a Water Supply 1 Water supply off or 1 Check and get terminate pressure too low recommended pressure b Float Switch 1 Connector 1 Reconnect disconnected 2 Defective switch 2 Check and replace 3 Float does not move 13 See IV D Float Switch freely Check and Cleaning C Control Board 1 Defective 1 See IV B Control Board Check 3 Compressor will a Magnetic Contactor 1 Bad contacts 1 Check for continuity and not start or stops replace operating 2 Coil winding open 2 Replace b Start Capacitor or Run 1 Defective 1 Replace Capacitor 36 3 Compressor will c Internal Overload 1 Loose terminal 1 Tighten or replace not start or stops Protector Open check operating continued 1 through 3 to the right 2 Voltage 2 Check and correct and d through f below 3 Dirty condenser d Starter 1 Bad contacts 1 Check and replace 2 Coil winding open 2 Replace e Compressor 1 Power supply not 1 Refer to nameplate and within specifications correct 2 Wiring to
71. rm Safeties AEN 18 4 Controls and En R aba aaa 19 a Default Dip Switch ERD ee 19 b Harvest Timer 54 dip switch 1 ayax nre 19 c Pump Out Timer S4 dip switch 3 amp 4 1 ecco 20 d Pump Out Frequency Control S4 dip switch 5 amp 6 20 e Bin Control Selector 54 dip switch 7 21 f Factory Use 54 dip switch B EE 21 g Freeze Timer S4 dip switch 9 amp 10 21 D BIMGONTO EE 22 E de dcs T Q 22 Us ln Uc I ee 22 Scil 22 IL rie Neie tg EE 23 A Water Circuit and Refrigeration Circuit ouod to ratu bi pops miza gEgeg 23 1 KM 2500SWH3 water cooled aaa alaya d d E s ni 23 2 KM 2500SRH3 remote air cooled b b s yasab amala bapas 24 Coul Yo NB Te EE 25 1 KM 2500SWH3 water cooled 25005 remote air cooled 25 C Performance Dala a a E E s RS 26 1 KM 2500SWH3 26 8 KM 2500SRH3 remote air cooled 7 7 27 IV Service Ee ue 28 A Diagnostic PIOOGBUUNG saba qaa toad toic ott tamea undi na M aaa lz tu MAT SER 28 B Control Board CMG CK a 31 C nee Mere
72. soap bubbles to check for leaks Add a trace of refrigerant to the system if using an electronic leak detector and then raise the pressure using nitrogen gas 140 PSIG DO NOT use R 404A as a mixture with pressurized air for leak testing 13 Evacuate the system and charge it with refrigerant See the nameplate for the required refrigerant charge 14 Close the drain valve s Open the condenser water supply line shut off valve If connected to a closed loop water supply also open the condenser return outlet shut off valve 15 Check for water leaks 16 Replace the panels in their correct positions 17 Turn on the power supply 49 G Removal and Replacement of Remote Air Cooled Condenser CAUTION 1 Always install a new drier every time the sealed refrigeration system is opened 2 Do not replace the drier until after all other repair or replacement has been made Install the new drier with the arrow on the drier in the direction of the refrigerant flow 3 When brazing protect the drier by using a wet cloth to prevent the drier from overheating Do not allow the drier to exceed 250 F 121 C 1 2 3 4 5 6 Turn off the power supply Remove the icemaker panels Recover the refrigerant and store it in an approved container Remove the condenser unit panels Disconnect the condenser inlet and outlet piping wa Ta a Remove the screws securing the condenser to the base of the unit then re
73. tor Harvest Backup Timer Orange H TIMER LED on harvest gt 20 min for Check for open thermistor HGV not opening two cycles in a row TXV or LLV leaking by WRV leaking by low charge or inefficient Comp Freeze Timer Yellow F TIMER LED on freeze gt freeze timer Check for F S stuck closed up WV leaking setting for two cycles ina by HGV leaking by PM not pumping TXV not row feeding properly LLV not opening low charge Timer is factory set using HM not bypassing or inefficient Comp S4 dip switch 9 amp 10 To reset the above safeties press the ALARM RESET button with the power supply on 57 Lovv Voltage Red LED turns off if voltage protection 92VAC 596 or less operates High Voltage The control voltage safeties automatically reset 147VAC 5 or more when voltage is corrected Legend Comp compressor FMR fan motor remote F S float switch HGV hot gas valve HM headmaster C P R LLV liquid line valve PM pump motor TXV thermostatic expansion valve WRV water regulating valve WV inlet water valve 4 Controls and Adjustments CAUTION Dip switches are factory set Failure to maintain factory settings may adversely affect performance and warranty coverage For more information contact Hoshizaki Technical Support at 1 800 233 1940 a Default Dip Switch Settings The dip switches are factory adjusted to the following positions S4 Dip Switch p84 Dip Switch 194 Dip Switch No
74. ty and replace e Fuse Control Box 1 Blown 1 Check for short circuit and replace Control Switch 1 OFF or WASH 1 Move to ICE position position 2 Bad contacts 2 Check for continuity and replace g High Pressure Control 1 Bad contacts 1 Check for continuity and replace 2 Dirty air filter or 2 Clean condenser 3 Ambient or condenser 3 Reduce temperature water temperature too warm 4 Refrigerant 4 Recover evacuate and overcharged recharge 5 Fan not operating 5 See chart 1 7 except water cooled model 6 Refrigerant line or 6 Clean and replace drier components restricted 7 Condenser water 7 Check and get pressure too low or offf recommended pressure water cooled model 35 1 The icemaker will not h Control Transformer 1 Coil winding open or 11 Replace start continued shorted Wiring to Control Board 1 Loose connections or 1 Check for continuity and open replace Interlock Switch 1 Open position 1 Move to closed position Cleaning Valve 2 Bad contacts 2 Check for continuity and replace k Thermistor 1 Leads shorted or open 1 See IV E Thermistor and high temperature or harvest backup timer safety operates 1 beep or 2 beep alarm 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 m Inlet Water Valve 1 Mesh filter or o
75. ue tmm 32 D Float Switch Check and Cleaning uda soot 32 E Thermistor R ege 34 ee e SUC CN a r aaa Oo 35 V Removal and Replacement of Components 43 A Service for Refrigerant il 43 1 Refrigerant EEN ET 43 24 AZ E 44 3 Evacuation and Recharge 404 44 B Removal and Replacement of Compressor wwa 45 C Removal and Replacement of Expansion Vahe imani 46 D Removal and Replacement of Hot Gas Valve or Liquid Line Valve 47 E Removal and Replacement of 48 F Removal and Replacement of Water Cooled Condenser 49 G Removal and Replacement of Remote Air Cooled Condenser 50 H Removal and Replacement of Water Regulating Valve water cooled model 51 Adjustment of Water Regulating Valve Water Cooled Model 52 J Removal and Replacement of Headmaster Condensing Pressure Regulator C P R Remote Air Cooled Model T c 52 K Removal and Replacement 810 53 L Removal and Replacement of Fan Motor Remote Air Cooled Model 54 M Removal and Replacement of Inlet Water Valve EE 54 N Removal and Replacement of Pump Motor 55 O Removal and Replacement of Control Board

Hoshizaki KM-2500SRH3 User's Manual

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