Hoshizaki
Hoshizaki America, Inc.
Modular Crescent Cuber
Models
KM-650MAH
KM-650MWH
KM-650MRH
“A Superior Degree
of Reliability”
SERVICE MANUAL
www.hoshizaki.com
™
Number: 73147
Issued: 12-12-2006
IMPORTANT
Only qualified service technicians should attempt to service or maintain this
unit. No such service or maintenance should be undertaken until the technician
has thoroughly read this Service Manual.
HOSHIZAKI provides this manual primarily to assist qualified service technicians in the
service and maintenance of the unit.
Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call, write or send an e-mail message to the HOSHIZAKI Technical
Support Department for assistance.
HOSHIZAKI AMERICA, INC.
618 Highway 74 South
Peachtree City, GA 30269
Attn: HOSHIZAKI Technical Support Department
Phone: 1-800-233-1940 Technical Service
(770) 487-2331
Fax: 1-800-843-1056
(770) 487-3360
E-mail: techsupport@hoshizaki.com
Web Site: www.hoshizaki.com
NOTE: To expedite assistance, all correspondence/communication MUST include the following information:
• Model Number
• Serial Number
• Complete and detailed explanation of the problem
Please review this manual. It should be read carefully before the icemaker is serviced or
maintenance operations are performed. Only qualified service technicians should service
and maintain the icemaker. This manual should be made available to the technician prior to
service or maintenance.
CONTENTS
I. Specifications....................................................................................................................... 5
A. Icemaker........................................................................................................................ 5
1. KM-650MAH (air-cooled).......................................................................................... 5
2. KM-650MWH (water-cooled).................................................................................... 6
3. KM-650MRH (remote air-cooled)............................................................................. 7
B. Condensing Unit............................................................................................................. 8
1. URC-5F.................................................................................................................... 8
II. General Information.......................................................................................................... 10
A. Construction................................................................................................................. 10
1. KM-650MAH (air-cooled)........................................................................................ 10
2. KM-650MWH (water-cooled).................................................................................. 11
3. KM-650MRH (remote air-cooled)........................................................................... 12
B. Sequence of Operation................................................................................................ 13
1. One Minute Fill Cycle............................................................................................. 13
2. Initial Harvest Cycle . ............................................................................................. 13
3. Freeze Cycle ......................................................................................................... 13
4. Pump-Out Cycle .................................................................................................... 13
5. Normal Harvest Cycle ........................................................................................... 13
C. Control Board............................................................................................................... 15
1. Control Board Layout.............................................................................................. 16
2. Features................................................................................................................. 17
a) Maximum Water Supply Period – 6 minutes........................................................ 17
b) Harvest Backup Timer and Freeze Timer............................................................ 17
c) High Temperature Safety..................................................................................... 17
d) Low Water Safety................................................................................................ 17
e) High Voltage and Low Voltage Cut-outs.............................................................. 17
f) LED Lights and Audible Alarm Safeties................................................................ 18
3. Controls and Adjustments...................................................................................... 19
a) Default Dip Switch Settings................................................................................. 19
b) Harvest Control – Thermistor.............................................................................. 19
c) Harvest Timer (dip switch 1 & 2).......................................................................... 20
d) Pump-Out Timer (dip switch 3 & 4)..................................................................... 20
e) Pump-Out Frequency Control (dip switch 5 & 6)................................................. 21
f) Freeze Timer (dip switch 9 & 10).......................................................................... 21
g) Bin Control........................................................................................................... 21
4. Control Board Check Procedure............................................................................. 22
5. Control Board Replacement................................................................................... 22
III. Technical Information....................................................................................................... 23
A. Water Circuit and Refrigeration Circuit......................................................................... 23
1. KM-650MAH (air-cooled)........................................................................................ 23
2. KM-650MWH (water-cooled).................................................................................. 24
3. KM-650MRH (remote air-cooled)........................................................................... 25
B. Wiring Diagrams........................................................................................................... 26
1. KM-650MAH (air-cooled) and KM-650MWH (water-cooled).................................. 26
2. KM-650MRH (remote air-cooled)........................................................................... 27
C. Performance Data........................................................................................................ 28
1. KM-650MAH (air-cooled)........................................................................................ 28
2. KM-650MWH (water-cooled).................................................................................. 29
3. KM-650MRH (remote air-cooled)........................................................................... 30
IV. Service Diagnosis............................................................................................................ 31
A. 10-Minute KM Diagnostic Procedure .......................................................................... 31
B. Diagnostic Charts......................................................................................................... 32
1. No Ice Production................................................................................................... 32
2. Evaporator is Frozen Up......................................................................................... 36
3. Low Ice Production................................................................................................. 37
4. Abnormal Ice.......................................................................................................... 37
5. Other....................................................................................................................... 37
V. Removal and Replacement of Components..................................................................... 39
A. Service for Refrigerant Lines....................................................................................... 39
1. Refrigerant Recovery.............................................................................................. 39
2. Evacuation and Recharge (R-404A)....................................................................... 39
B. Brazing......................................................................................................................... 40
C. Removal and Replacement of Compressor................................................................. 40
D. Removal and Replacement of Drier............................................................................. 41
E. Removal and Replacement of Expansion Valve........................................................... 42
F. Removal and Replacement of Hot Gas Valve and Line Valve . .................................... 43
G. Removal and Replacement of Evaporator................................................................... 44
H. Removal and Replacement of Water Regulating Valve - Water Cooled Model Only.... 44
I. Adjustment of Water Regulating Valve - Water-Cooled Model Only.............................. 45
J. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.)
- Remote Air-Cooled Model Only............................................................................... 46
K. Removal and Replacement of Thermistor.................................................................... 47
L. Removal and Replacement of Fan Motor..................................................................... 47
M. Removal and Replacement of Inlet Water Valve.......................................................... 48
N. Removal and Replacement of Pump Motor................................................................. 48
O. Removal and Replacement of Spray Tubes................................................................. 49
VI. Cleaning and Maintenance Instructions.......................................................................... 50
A. Cleaning and Sanitizing Procedures............................................................................ 50
1. Cleaning Procedure................................................................................................ 51
2. Sanitizing Procedure - Following Cleaning Procedure........................................... 52
B. Maintenance................................................................................................................. 52
C. Preparing the Icemaker for Long Storage.................................................................... 53
I. Specifications
A.SPECIFICATION
Icemaker
NO. 06A019
ITEM:
HOSHIZAKI MODULAR CRESCENT CUBER
1. KM-650MAH
(air-cooled)
MODEL:
KM-650MAH
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day ( kg/day )
Reference without *marks
SHAPE OF ICE
ICE PRODUCTION PER CYCLE
APPROXIMATE STORAGE CAPACITY
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
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
DRAWING NO. (DIMENSION)
ISSUED: 10/10/2006
208-230/60/1 (3 wire with neutral for 115V)
6.6 A ( 5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
Ambient
WATER TEMP. (°F)
Temp.(°F)
50
70
90
70
*589 (267)
566 (257)
526 (238)
80
572 (259)
537 (243)
490 (222)
90
566 (257)
*512 (232)
467 (212)
100
555 (252)
501 (227)
426 (193)
Crescent Cube
13.5 lbs. (6.1 kg) 720 pcs.
N/A
90/70°F
70/50°F
1240(5.8)
1100(4.5)
108(21.1)
257(43.7)
22" x 27-3/8" x 37-7/16" (560 x 695 x 950 mm)
Stainless Steel, Galvanized Steel (Rear)
Net 169 lbs. (77 kg), Shipping 200 lbs. (91 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 RS55C2E-CAV
Air-Cooled , Fin and tube type
Vertical type, Stainless Steel and Copper
Thermostatic Expansion Valve
R-404A, 1 lb. 8.7 oz. (700g)
High 467PSIG, Low 230PSIG
High Voltage Cut-out ( Internal )
Auto-reset Overload Protector ( Internal )
Auto-reset High Pressure Control Switch
Float Switch
N/A
Ice Storage Bin
VOLTAGE RANGE
187 - 253 V
AMBIENT TEMP.
45 -100° F
WATER SUPPLY TEMP.
45 - 90° F
WATER SUPPLY PRESSURE
10 - 113 PSIG
3A1897
We reserve the right to make changes in specifications and design without prior notice.
Note: We reserve the right to make changes in specifications and design without prior
notice.
SPECIFICATION NO. 06A020
2. KM-650MWH
ITEM:
HOSHIZAKI (water-cooled)
MODULAR CRESCENT CUBER
ISSUED: 10/10/2006
MODEL: KM-650MWH
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day ( kg/day )
Reference without *marks
SHAPE OF ICE
ICE PRODUCTION PER CYCLE
APPROXIMATE STORAGE CAPACITY
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
WATER COOLED CONDENSER
gal./24HR (gal./100 lbs.)
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
DRAWING NO. (DIMENSION)
208-230/60/1 (3 wire with neutral for 115V)
5.3 A ( 5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
Ambient
WATER TEMP. (°F)
Temp.(°F)
50
70
70
*680 (308)
675 (306)
80
676 (307)
668 (303)
90
675 (306)
*662 (300)
100
651 (295)
647 (294)
Crescent Cube
14.8 lbs. (6.7 kg) 720 pcs.
N/A
90/70°F
70/50°F
1050(3.8)
1020(3.6)
149(22.5)
254(37.4)
741(112)
408(60)
90
626 (284)
595 (270)
598 (271)
540 (245)
22" x 27-3/8" x 37-7/16" (560 x 695 x 950 mm)
Stainless Steel, Galvanized Steel (Rear)
Net 169 lbs. (77 kg), Shipping 200 lbs. (91 kg)
Permanent - Connection
Inlet
1/2" FPT
Condenser Inlet 1/2" FPT
Outlet
3/4" FPT
Condenser Outlet 3/8" FPT
3/8" OD Tube
Float Switch
Hot Gas and Water, Thermistor and Timer
Timer Controlled. Overflow Pipe
Pressure Regulator
Thermostat
Hermetic, Model RS55C2E-CAV
Water-cooled, Tube in tube type
Vertical type, Stainless Steel and Copper
Thermostatic Expansion Valve
R-404A, 1 lb. 5.7 oz. (615g)
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
3A1898
Note: We reserve the right to make changes in specifications and design without prior
We reserve
the right to make changes in specifications and design without prior notice.
notice.
ENG.F-011.1.0205
SPECIFICATION DATA NO. 06A021
ITEM:
HOSHIZAKI MODULAR CRESCENT CUBER
3. KM-650MRH (remote air-cooled)
MODEL: KM-650MRH
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day ( kg/day )
Reference without *marks
SHAPE OF ICE
ICE PRODUCTION PER CYCLE
APPROXIMATE STORAGE CAPACITY
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
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
DRAWING NO. (DIMENSION)
ISSUED: 10/10/2006
208-230/60/1 (3 wire with neutral for 115V)
7.1 A ( 5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
Ambient
WATER TEMP. (°F)
Temp.(°F)
50
70
90
70
*615 (279)
597 (271)
556 (252)
80
601 (273)
574 (260)
523 (237)
90
597 (271)
*554 (251)
506 (230)
100
583 (264)
543 (246)
462 (210)
Crescent Cube
14.1 lbs. (6.4 kg ) 720 pcs.
N/A
90/70°F
70/50°F
1250(5.4)
1150(4.5)
111(20.0)
266(43.2)
22" x 27-3/8" x 37-7/16" (560 x 695 x 950 mm)
Stainless Steel, Galvanized Steel (Rear)
Net 169 lbs. (77 kg), Shipping 200 lbs. (91 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 RS55C2E-CAV
Air-cooled Remote, Condenser Unit URC-5F
Vertical type, Stainless Steel and Copper
Thermostatic Expansion Valve
Condensing Pressure Regulator on URC-5F
R-404A,
5 lbs. 11 oz. (2580 g)
( Icemaker 3 lbs. 13 oz. Cond. Unit 1 lb. 14 oz. )
High 467 PSIG, Low 230 PSIG
High Voltage Cut-out ( Internal )
Auto-reset Overload Protector ( Internal )
Auto-reset High Pressure Control Switch
Float Switch
N/A
Ice Storage Bin, 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
3A1899
WeNote:
reserve
thereserve
right to make
changes
in specifications
without prior
notice.
We
the right
to make
changesand
in design
specifications
and
design
without prior
notice.
ENG.F-011.0.1196
B. Condensing Unit
1. URC-5F
24"
(610 mm.)
23-1/32"
(585 mm.)
15-11/16"
(398 mm.)
14-15/16"
(380 mm.)
14-1/8"
(358 mm.)
14-9/16"
(370 mm.)
17-1/8"
(435 mm.)
6/16" x 3/4" (10 mm. x 20 mm.)
4 x 2 (SLOTTED HOLES)
18-1/8"
(460 mm.)
20-15/32"
(520 mm.)
2-1/2"
(63 mm.)
17-7/8"
(454 mm.)
21-15/16"
(557 mm.)
14-15/16"
(380 mm.)
18-1/8"
(460 mm.)
19-11/16"
(500 mm.)
7/8" DIA. HOLE
(23 mm. DIA.)
6-5/16"
(160 mm.)
2-15/16"
(75 mm.)
ISSUED: 10/12/2006
SPECIFICATION NO. 06A022
ITEM: HOSHIZAKI REMOTE CONDENSER UNIT
Specifications
MODEL URC-5F
BEGINNING SERIAL NO. ________________
MODEL: URC-5F
ENDING SERIAL NO. ___________________
AC SUPPLY VOLTAGE
115/60/1 (Connection to Icemaker)
FAN MOTOR
115 V
EXTERIOR DIMENSIONS (WxDxH)
21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 454 mm)
DIMENSIONS INCLUDING LEGS (WxDxH)
24" x 18-1/8" x 32-13/16" (610 x 460 x 834 mm)
EXTERIOR FINISH
Galvanized Steel
WEIGHT
Net 61 lbs. ( 28 kg )
CONNECTIONS - ELECTRIC
Permanent - Connection
- REFRIGERANT
Total 1.3FLA
65W
Shipping 68 lbs. ( 31 kg )
Discharge Line 1-1/16"-12 UNF Fitting (#10 AEROQUIP)
Liquid Line
5/8"-18 UNF Fitting (#6 AEROQUIP)
CONDENSER
Air-cooled, Fin and tube type
FAN MOTOR PROTECTION
Thermal Protection
REFRIGERANT CONTROL
Condensing Pressure Regulator
REFRIGERANT CHARGE
R-404A
DESIGN PRESSURE
High 467 PSIG
OPERATING CONDITIONS
VOLTAGE RANGE
104 ~ 127 V
AMBIENT TEMP.
-20 ~ 122 °F
ACCESSORIES -SUPPLIED
DRAWING NO. (DIMENSION)
1 lb. 14 oz.
(850g)
Leg
2 pcs
Hex. Head Bolt w/Washer
8 x 16
8 pcs
Hex. Nut
8
8 pcs
441211
We reserve the right to make changes in specifications and design without prior notice.
Note: We reserve the right to make changes in specifications and design without prior
notice.
II. General Information
A. Construction
1. KM-650MAH (air-cooled)
Spray Tubes
Water Supply Inlet
Condenser
Control Box
Control Switch
Bin Control Thermostat
Fan Motor
Expansion Valve
Hot Gas Valve
Float Switch
Drier
Compressor
Water Pump
10
2. KM-650MWH (water-cooled)
Spray Tubes
Water Supply Inlet
Water Regulator Valve
Control Switch
Bin Control Thermostat
Control Box
Expansion Valve
Condenser
Float Switch
Water Pump
Drier
Hot Gas Valve
Compressor
11
3. KM-650MRH (remote air-cooled)
Spray Tubes
Water Supply Inlet
Junction Box
Control Box
Control Switch
Bin Control Thermostat
Receiver Tank
Hot Gas Valve
Expansion Valve
Drier
Float Switch
Compressor
Water Pump
Liquid Line Valve
12
B. Sequence of Operation
The steps in the sequence are as outlined below. When power is supplied, a 5 second
delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is
1, 4, 3, 2.
1. One Minute Fill Cycle
LED 4 is on. WV opens and the fill period begins. After 1 minute, the board checks for
a closed F/S. If F/S is closed, the harvest cycle begins. If not, WV will remain energized
through additional 1 minute cycles until water enters the sump and F/S closes. This serves
as a low water safety to protect the water pump.
2. Initial Harvest Cycle
LEDs 1, 4, and 2 are on. WV remains open, Comp and FMR energize, HGV opens,
and harvest begins. As the evaporator warms, the thermistor located on the suction line
checks for a 48°F (9°C) temperature. When 48°F (9°C) is reached, a 3.9 kΩ signal turns
the harvest over to the adjustable harvest timer which is factory set for normal conditions.
The timer has settings of 60, 90, 120, and 180 seconds (dip switch 1 & 2). The water valve
is open during harvest for a maximum of 6 minutes or the length of harvest, whichever is
shorter. When the harvest timer completes its count down, the harvest cycle is complete
and the freeze cycle starts. The minimum total time allowed by the board for a complete
harvest cycle is 2 minutes.
3. Freeze Cycle
LED 1 is on. Comp and FMR continue to run, PM and FMS energize, LLV opens, HGV
and WV close and the freeze cycle starts. For the first 5 minutes the control board will not
accept a signal from F/S. This 5 minute minimum freeze acts as a short cycle protection. At
the end of 5 minutes, F/S assumes control. As ice builds on the evaporator the water level
in the sump lowers. The freeze continues until F/S opens and terminates ice production.
4. Pump-Out Cycle
LEDs 1, 3, and 2 are on. Comp and FMR continue to run, HGV opens, LLV closes, and
FMS deenergizes. PM stops for 2 seconds and reverses, taking water from the bottom of
the sump 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 tube
to power flush the F/S. When the pump-out timer stops counting, the pump out is complete.
Pump out always occurs on the 2nd harvest after startup. Then, depending on the control
board setting, pump out occurs every cycle, or every 2nd, 5th or 10th cycle (dip switch 5 &
6).
5. Normal Harvest Cycle
LEDs 1, 4, and 2 are on. Comp and FMR continue to run, HGV remains open and WV
opens. As the evaporator warms, the thermistor reaches 48°F (9°C). The control board
then receives the thermistor's 3.9 kΩ signal and starts the harvest timer. The water valve
is open during harvest for a maximum of 6 minutes or the length of harvest, whichever is
shorter. When the harvest timer completes its count down, the harvest cycle is complete
and the next freeze cycle starts. The unit continues to cycle through 3, 4 and 5 sequence
until the bin control senses ice and shuts the unit down.
Legend: Comp–compressor; FMR–remote fan motor; FMS–self-contained fan motor;
F/S–float switch; HGV–hot gas valve; LLV–Liquid Line Valve; PM–pump motor; WV–inlet water valve
13
14
F/S open
WV Energized
F/S Check
1. One Minute
Fill Cycle
2. Harvest Cycle
Comp energized
HGV energized
FMR energized
WV continues
F/S closed
Thermistor in
control
3. Freeze Cycle
Comp continues
FMR continues
HGV de-energized
WV de-energized
PM energized
FMS energized
F/S closed
5 minute timer
in control
Freeze cycle
operation turned
over to F/S
F/S in
control
The WASH position on the control switch is used when cleaning and sanitizing the unit. When in the WASH
position, power is supplied to the pump motor. With the cleaning valve closed, the cleaner and sanitizer flow
over the outside of the evaporator plate assembly. With the cleaning valve open, the cleaner and sanitizer
flow over both the outside and the inside of the evaporator plate assembly.
Note: Close the cleaning valve after cleaning and sanitizing are complete, otherwise the unit will not re-start when the control switch is placed in the ICE position.
Components Energized when the Control Switch is in the WASH Position
Pump motor stops
for 2 sec. and then
reverses for 10/20 sec.
each 1, 2, 5, or 10 cycles.
Comp continues
FMR continues
HGV energized
FMS de-energized
4. Pump-Out
• Minimum freeze time: 5 minutes
• Maximum freeze time: freeze timer setting
Cycle
If F/S is open, compressor stops and cycle returns to 1 minute fill
F/S open
Thermistor temp
reaches 48°F (9°C)
(3.9 kΩ or less)
Harvest timer starts
F/S Check
1 to 3 minute timer
in control
• Maximum inlet water valve time: 6 minutes
• Maximum harvest time: 20 minutes
Legend:
Comp - compressor
FMR - remote fan motor
FMS - self-contained fan motor
F/S - float switch
HGV - hot gas valve
PM - pump motor
WV - inlet water valve
"E" board will have
5 second delay
Initial startup always
begins here
Cycle Steps
KM-650MAH, KM-650MWH, KM-650MRH Sequence Flow Chart and Component Operation
C. Control Board
• A HOSHIZAKI exclusive solid-state control is employed in KM-650MAH, KM‑650MWH
and KM‑650MRH Modular Crescent Cubers.
• All models are pretested and factory-adjusted.
CAUTION
1. Fragile, handle very carefully.
2. A 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 when handling or replacing the board.
3. Do not touch the electronic devices on the board or the back of the board to
prevent damage to the board.
4. Do not change wiring and connections. Do not misconnect K3, K4 and K5,
because the same connector is used for the thermistor and float switch. K4 is
not connected.
5. Always replace the whole board assembly if it goes bad.
6. Do not short out power supply to test for voltage.
15
1. Control Board Layout
Control Products "E" Control Board
Alarm Reset Switch
Dip Switch
Output Test Switch
(used to test relays on board)
Backup Freeze
Timer LED
Connector K3
Harvest Control
(thermistor)
Backup Harvest
Timer LED
Connector K4
Open
(not connected)
Alarm Buzzer
Microprocessor
(board revision level
indicated by last 2
digits on label)
Power LED
(lights when
power is supplied
to the board)
Relay LEDs (4)
(indicate which
relays are energized
as listed below)
Connector K5
Float Switch
Part Number
Connector K1
LED 2
Hot Gas Valve (HGV)
Self-Contained Fan
Motor (FMS) (FMS
off when LED on)
Pins #1 through #10
#1, 9 Magnetic Contactor
#2 Hot Gas Valve
#3 Line Valve
Self-Contained Fan Motor (FMS)
#4 Pump Motor (icemaking)
#5 Pump Motor (drain)
#6 Water Valve
#7, 10 Power (line, bin control)
#8 Open
LED 3
Pump Motor (PM)
(on at pump out only)
LED 4
Water Valve (WV)
LED 1
Compressor (Comp)
Remote Fan Motor
(FMR)
Switch for "C" board
and "ALPINE" board
(service boards only)
Transformer
Connector
Control Board
Part Number
2A1410-01 (factory); 2A1410-02 (service)
Type
HOS-001A (Control Products - 10 Pin)
16
2. Features
a) Maximum Water Supply Period – 6 minutes
Inlet water valve opening, in the harvest cycle, is limited by the harvest timer. The water
valve cannot remain open longer than the maximum period. The water valve can close in
less than six minutes if the harvest cycle is completed.
b) Harvest Backup Timer and Freeze Timer
The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest
cycle takes more than 20 minutes to complete. The control board will signal this problem
using 2 beeps every 3 seconds.
The freeze timer shuts down the icemaker if, for two cycles in a row, the freeze cycle
takes longer than the time specified to complete. The control board will signal this
problem using 3 beeps every 3 seconds. The time is factory set using dip switches 9 &
10.
The reset button on the control board must be pressed with power on to reset either of
these safeties.
c) High Temperature Safety
The temperature of the suction line in the refrigeration circuit is limited by the high
temperature safety. This protects the unit from excessively high temperatures. If the
evaporator temperature rises above 127 ± 7°F (53 ± 4°C), the thermistor operates the
safety. This shuts down the circuit and the icemaker automatically stops.
The control board will signal this problem using 1 beep every 3 seconds. The reset button
on the control board must be pressed with power on to reset the safety.
d) Low Water Safety
If the pump motor is operated without water, the mechanical seal can fail. To prevent this
type of failure, the control board checks the position of the float switch at the end of the
initial one minute water fill cycle and at the end of each harvest cycle.
If the float switch is in the up position (electrical circuit closed), the control board changes
to the ice making cycle. If the float switch is in the down position (electrical circuit open),
the control board changes to additional one minute water fill cycles until water enters the
sump and the float switch closes. When the float switch closes, the control board changes
to the ice making cycle. The unit will not start without adequate water in the sump. 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 icemaker are limited by the
high voltage and low voltage cut-outs.
If miswiring (especially on single phase 3 wire models) causes excessive voltage (147Vac
±5% or more) on the control board, the high voltage cut-out shuts down the circuit
in 3 seconds and the icemaker automatically stops. The control board will signal this
problem using 7 beeps every 3 seconds.
The icemaker also automatically stops in cases of insufficient voltage (92Vac ±5% or
less). The control board will signal this problem using 6 beeps every 3 seconds.
When the proper supply voltage is resumed, the icemaker automatically starts running
again.
17
f) LED Lights and Audible Alarm Safeties
The red LED indicates proper control voltage and will remain on unless a control voltage
problem occurs. At startup a 5 second delay occurs while the board conducts an internal
timer check. A short beep occurs when the power switch is turned OFF.
The green LEDs 1 through 4 energize and sequence from initial startup as listed in the
table below. Note that the order of the LEDs from the outer edge of the board is 1, 4, 3,
2. For more information, see "II.B. Sequence of Operation."
Sequence Step
LED
1 Minute Fill Cycle 4
Harvest Cycle
1, 4, and 2
Freeze Cycle
1
Reverse Pump Out 1, 3, and 2
Energized
Components
Time LEDs are On
Min.
Max.
Avg.
60 seconds
20 minutes 3 to 5 minutes
WV
WV, HGV,
2 minutes
Comp, FMR
Comp, PM, 5 minutes freeze timer 30 to 35 minutes
FMR/FMS,
setting
LLV
Comp, HGV, 10 seconds 20 seconds factory setting
PM, FMR
The built in safeties shut down the unit and have alarms as follows:
No. of Beeps
Type of Alarm
(every 3 sec.)
1
High Evaporator Temp.
(temperature > 127°F)
(53°C)
Notes
Check for harvest problem (stuck HGV or
relay), hot water entering unit, stuck HM,
or shorted thermistor.
2
Harvest Backup Timer
(harvest > 20 min. for two
cycles in a row)
Orange LED marked H TIMER lights up.
Check for open thermistor, HGV not
opening, TXV leaking by, low charge, or
inefficient compressor.
3
Freeze Timer
(freeze > specified setting
for two cycles in a row)
Timer is factory set using
dip switches 9 & 10
Yellow LED marked F TIMER lights up.
Check for F/S stuck closed (up), WV
leaking by, HGV leaking by, TXV not
feeding properly, low charge, HM not
bypassing, or inefficient compressor.
To manually reset the above safeties, press the alarm reset button with the power
supply on.
6
Low Voltage
(92Vac ±5% or less)
7
High Voltage
(147Vac ±5% or more)
Red LED will turn off if voltage protection
operates.
The control voltage safeties automatically
reset when voltage is corrected.
Legend: Comp–compressor; FMR–remote fan motor; FMS–self-contained fan motor;
F/S–float switch; HGV–hot gas valve; HM–headmaster (C.P.R.); LLV–Liquid Line Valve; PM–pump motor; TXV–thermostatic expansion valve; WV–inlet water valve
18
3. Controls and Adjustments
a) Default Dip Switch Settings
The dip switch is factory-adjusted to the following positions:
Dip Switch No.
1
2
3
4
5
6
7
8
9
10
KM-650MAH
OFF OFF OFF OFF ON
ON OFF OFF OFF OFF
KM-650MWH
OFF OFF OFF OFF ON
ON OFF OFF OFF OFF
KM-650MRH
OFF OFF OFF OFF ON
ON OFF OFF ON OFF
Freeze Timer (9 & 10)
Normally in the OFF position.
Pump-Out Frequency Control (5 & 6)
Pump-Out Timer (3 & 4)
Harvest Timer (1 & 2)
b) Harvest Control – Thermistor
A thermistor (semiconductor) is used for a harvest control sensor. The resistance varies
depending on the suction line temperatures. The thermistor detects the temperature of
the evaporator outlet to start the harvest timer. No adjustment is required. If necessary,
check for resistance between thermistor leads, and visually check the thermistor
mounting, located on the suction line next to the evaporator outlet.
Temperature (°F) Temperature (°C)
0
10
32
50
70
90
-18
-12
0
10
21
32
Resistance (kΩ)
14.401
10.613
6.000
3.871
2.474
1.633
Check a thermistor for resistance by using the following procedure:
1) Disconnect the connector K3 on the board.
2) Remove the thermistor. See "V.K. Removal and Replacement of Thermistor."
3) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3
minutes.
4) Check for a resistance between thermistor leads. Normal reading is within 3.5 to 7 kΩ.
Replace the thermistor if it exceeds the normal reading.
19
c) Harvest Timer (dip switch 1 & 2)
The harvest timer starts counting when the thermistor reads 48°F (9°C) at the
evaporator outlet.
No adjustment is required under normal use, as the harvest timer is adjusted to the
suitable position. However, a setting longer than the factory setting may be advised in
cases where the flush provided at harvest needs to be prolonged for extra cleaning.
Before changing this setting, call the HOSHIZAKI Technical Support Department at
1‑800‑233‑1940 for recommendations. Keep in mind that setting the harvest timer to a
longer setting will decrease 24 hour production.
Dip Switch Setting
Time
(seconds)
No. 1
No. 2
OFF
OFF
60
ON
OFF
90
OFF
ON
120
ON
ON
180
d) Pump-Out Timer (dip switch 3 & 4)
When a freeze cycle is completed, the pump motor stops, and the icemaker resumes
operation in 2 seconds. Then, during cycles when a pump out is called for, the pump
motor drains the water tank for the time determined by the pump-out timer. The pumpout timer also acts in place of the harvest timer during cycles with a pump out.
The pump-out timer is factory-adjusted, and no adjustment is required.
Dip Switch Setting Time (seconds)
No. 3
OFF
ON
OFF
ON
T1
No. 4
OFF
OFF
ON
ON
10
10
10
20
T2
150
180
120
180
T1: Time to drain the water tank
T2: Harvest timer at pump out
Pump out always occurs on the 2nd harvest after startup. Then, depending on the pumpout frequency control setting (dip switch 5 & 6), pump out occurs every cycle, or every
2nd, 5th or 10th cycle.
20
e) Pump-Out Frequency Control (dip switch 5 & 6)
The pump motor drains the water tank at the frequency set by the pump-out frequency
control.
The pump-out frequency control is factory-adjusted to drain the water tank every 10
cycles, and no adjustment is required. However, where water quality is bad and the
icemaker needs a pump drain more often, the pump-out frequency can be adjusted as
shown in the table below.
Dip Switch Setting
No. 5
OFF
ON
OFF
ON
No. 6
OFF
OFF
ON
ON
Frequency
every cycle
every 2 cycles
every 5 cycles
every 10 cycles
f) Freeze Timer (dip switch 9 & 10)
CAUTION
Adjust to proper specification, or the unit may not operate correctly.
The freeze timer setting determines the maximum allowed freeze time to prevent
possible freeze-up issues. Upon termination of freeze timer, machine initiates the harvest
cycle. After 2 consecutive timer terminations, machine will shut down, possibly indicating
a problem.
The freeze timer is factory adjusted and no adjustment is required.
Dip Switch Setting
No. 9
OFF
OFF
ON
ON
No. 10
OFF
ON
OFF
ON
Time
(minutes)
60
50
70
60
g) Bin Control
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 icemaker operates continuously
even if the ice storage bin is filled with ice. Setting in the prohibited range might
cause severe damage to the icemaker resulting in failure.
No adjustment is required under normal use, as the bin control is factory-adjusted. Adjust
it, if necessary, so that the icemaker stops automatically within 10 seconds after ice
contacts the bin control thermostat bulb.
21
4. Control Board Check Procedure
Before replacing a control board that does not show a visible defect and that you suspect
is bad, always conduct the following check procedure. This procedure will help you verify
your diagnosis.
1) Check the dip switch settings to assure that #3, 4, 7, 8, 9, & 10 are in the factory default
position. On units with a slide-type output test switch, the output test switch (S3) should
be OFF. Switches 1, 2, 5, & 6 are cleaning adjustments and the settings are flexible.
2) Turn the control switch to ICE and check for proper control voltage. If the red LED is ON,
the control voltage is good. If the red LED is OFF, check the control transformer circuit.
3)Check the 115 volt input at the 10-pin connector. Check the brown wire at pin #10 to a
white neutral wire for 115 volts. (Always choose a white neutral wire to establish a good
neutral connection when checking voltages.) A jumper also feeds 115 volts into pin #7.
If no voltage is present, check the 115 volt supply circuit.
4) The output test switch provides a relay sequence test. On units with a slide-type output
test switch, move the control switch to the OFF position, move the output test switch to
the ON position, then move the control switch to the ICE position. On units with a pushtype output test switch, make sure the control switch is in the ICE position, then press
the output test switch. The correct lighting sequence should be none, 2, 3, 4, 1, and 4,
normal sequence every 5 seconds. Components (e.g., the compressor) will cycle during
the test. Note that the order of the relays from the outer edge of the board is 1, 4, 3, 2.
Note: If the LEDs light in a different sequence or the 5–second interval does not occur,
the control board is bad and should be replaced.
5) After checking the sequence, place the output test switch back in the OFF position
on units with a slide-type switch. The output test switch must remain in the OFF
position during normal operation. On units with a push-type output test switch, the unit
automatically resumes normal operation after the test. The unit begins normal operation
with the 1 minute fill cycle.
5. Control Board Replacement
The application switch located between relay X3 & X4 must be set to match the original
board application. Place this switch in the ALP position if there is no white wire supplied
to the K1 connector. If there is a white wire, place the switch in the C position. If this
switch is placed in the wrong position either the compressor contactor will remain
energized with the control switch OFF or the unit will not start.
The dip switches should be adjusted to the factory default settings as outlined in this
manual. Dip switch #8 must remain in the OFF position.
22
III. Technical Information
A. Water Circuit and Refrigeration Circuit
1. KM-650MAH (air-cooled)
23
2. KM-650MWH (water-cooled)
24
3. KM-650MRH (remote air-cooled)
25
B. Wiring Diagrams
1. KM-650MAH (air-cooled) and KM-650MWH (water-cooled)
*
Cut-out
Cut-in
* Pressure Switch
Air-Cooled Model
Water-Cooled Model
412±210 PSIG
384±210 PSIG
327±21 PSIG
284±21 PSIG
26
12V
2. KM-650MRH (remote air-cooled)
*
* Pressure Switch
Cut-out
412±21
0 PSIG
Cut-in
327±21 PSIG
27
12V
C. Performance Data
PERFORMANCE
DATA
NO. 06A019
1. KM-650MAH
(air-cooled)
ITEM:
HOSHIZAKI MODULAR CRESCENT CUBER
ISSUED: 10/10/2006
MODEL: KM-650MAH
APPROXIMATE ICE
PRODUCTION PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
WATER TEMP. (ºF/ºC)
AMBIENT TEMP.
(ºF/ºC)
50/10
90/32
589
572
267
259
566
537
257
243
526
490
238
222
90/32
100/38
70/21
80/27
566
555
257
252
512
501
232
227
467
426
212
193
90/32
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
100/38
70/21
80/27
90/32
257
224
214
gal./day m3/day
FREEZING CYCLE TIME
100/38
163
min.
HARVEST CYCLE TIME
70/21
70/21
80/27
1100
1131
1141
1195
1170
1209
1141
1240
1261
1138
0.97
0.85
0.81
214
156
108
0.62
105
1245
0.81
0.59
0.41
190
153
95
0.40
84
1280
0.32
70/21
80/27
30
31
32
35
35
38
90/32
100/38
70/21
32
33
4.6
37
38
3.9
40
43
3.6
80/27
90/32
4.1
3.9
3.0
2.2
3.0
2.1
3.1
2.2
0.72
0.58
0.36
min.
HEAD PRESSURE
100/38
70/21
80/27
90/32
225
241
246
15.8
17.0
17.3
246
275
298
17.3
19.3
21.0
270
295
320
19.0
20.7
22.5
PSIG kg/cm2G
SUCTION PRESSURE
100/38
249
17.5
303
21.3
341
24.0
70/21
80/27
90/32
53
54
55
3.7
3.8
3.9
55
57
59
3.9
4.0
4.2
58
61
63
4.1
4.3
4.4
100/38
56
3.9
60
4.2
67
4.7
PSIG
2
kg/cm G
TOTAL HEAT OF REJECTION FROM CONDENSER
2.0
10,600 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
Note: Pressure data is recorded at 5 minutes into freezing cycle.
The data not in bold should be used for reference only.
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.
28
PERFORMANCE DATA NO. 06A020
ITEM:
HOSHIZAKI MODULAR
CRESCENT CUBER
2. KM-650MWH
(water-cooled)
ISSUED: 10/10/2006
MODEL: KM-650MWH
APPROXIMATE ICE
PRODUCTION PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
WATER TEMP. (ºF/ºC)
AMBIENT TEMP.
(ºF/ºC)
50/10
90/32
70/21
80/27
680
676
308
307
675
668
306
303
626
595
284
270
90/32
100/38
70/21
80/27
675
651
306
295
662
647
300
294
598
540
271
245
90/32
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
100/38
70/21
80/27
90/32
662
713
729
gal./day m3/day
FREEZING CYCLE TIME
100/38
980
min.
HARVEST CYCLE TIME
70/21
1020
1027
1029
1040
1036
1044
1029
1050
1055
1028
2.51
2.70
2.76
729
817
890
3.71
1023
1051
2.76
3.09
3.37
1173
1457
1457
3.87
1977
1060
7.49
70/21
80/27
27
28
28
30
30
32
90/32
100/38
70/21
28
29
4.7
31
31
4.1
33
35
3.7
80/27
90/32
4.3
4.1
3.4
2.8
3.1
2.5
3.4
2.7
4.44
5.52
5.52
2.1
min.
HEAD PRESSURE
100/38
70/21
80/27
90/32
231
231
231
16.2
16.2
16.2
231
231
231
16.2
16.2
16.2
238
242
240
16.7
17.0
16.9
PSIG kg/cm2G
SUCTION PRESSURE
100/38
235
16.5
233
16.4
249
17.5
70/21
80/27
90/32
50
51
51
3.5
3.6
3.6
51
54
56
3.6
3.8
3.9
53
54
56
3.7
3.8
4.0
100/38
51
3.6
56
3.9
57
4.0
PSIG
2
kg/cm G
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
WATER FLOW FOR CONDENSER
10,000 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
77 gal./h [AT 100ºF (38ºC) / WT 90ºF (32ºC)]
PRESSURE DROP OF COOLING WATER LINE
less than 10 PSIG
Note: Pressure data is recorded at 5 minutes into freezing cycle.
The data not in bold should be used for reference only.
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.
29
ENG.F-011.1.0205
PERFORMANCE DATA NO. 06A021
ITEM: HOSHIZAKI MODULAR CRESCENT CUBER
ISSUED: 10/10/2006
MODEL:
KM-650MRH
3. KM-650MRH
(remote air-cooled)
APPROXIMATE ICE
PRODUCTION PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
WATER TEMP. (ºF/ºC)
AMBIENT TEMP.
(ºF/ºC)
50/10
279
273
597
574
271
260
556
523
252
237
90/32
100/38
70/21
80/27
597
583
271
264
554
543
251
246
506
462
230
210
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
100/38
70/21
80/27
90/32
266
231
220
gal./day m3/day
FREEZING CYCLE TIME
100/38
169
min.
HEAD PRESSURE
PSIG kg/cm2G
SUCTION PRESSURE
PSIG
kg/cm2G
90/32
615
601
90/32
min.
HARVEST CYCLE TIME
70/21
70/21
80/27
1150
1172
1179
1218
1212
1247
1179
1250
1281
1183
1.01
0.87
0.83
220
161
111
0.64
108
1257
0.83
0.61
0.42
198
160
100
0.41
91
1310
0.75
0.61
0.38
0.34
70/21
80/27
29
30
31
33
33
36
90/32
100/38
70/21
31
32
4.6
34
35
3.8
37
40
3.6
80/27
90/32
4.0
3.8
2.8
2.0
3.0
2.0
100/38
70/21
80/27
214
229
15.1
16.1
233
258
16.4
18.2
254
275
17.8
19.4
90/32
100/38
233
235
16.4
16.6
279
283
19.6
19.9
298
315
21.0
22.2
70/21
80/27
90/32
51
53
53
3.6
3.7
3.8
53
56
58
3.8
3.9
4.1
56
59
61
4.0
4.1
4.3
100/38
54
3.8
59
4.2
64
4.5
3.0
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
CONDENSER VOLUME
2.0
2.0
9400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1600 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
40 CU. IN (URC-5F)
Note: Pressure data is recorded at 5 minutes into freezing cycle.
The data not in bold should be used for reference only.
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.
30
IV. Service Diagnosis
A. 10-Minute KM Diagnostic Procedure
The 10 minute check out procedure is basically a sequence check which can be used
at unit start-up or for system diagnosis. Using this check out procedure will allow you
to diagnose electrical system and component failures in approximately 10 minutes
under normal operating conditions of 70°F or warmer air and 50°F or warmer water
temperatures. Before conducting a 10 minute checkout, check for correct installation,
proper voltage per unit nameplate and adequate water supply. As you go through the
procedure, check to assure the components energize and de-energize correctly. If not,
those components and controls are suspect. Check for voltage at the 10-pin connector.
1) Turn power OFF and access the control box.
2) Turn power ON and place the control switch in ICE position. A 5 second delay occurs.
3) One Minute Fill Cycle – The inlet water valve is energized. After 1 minute, the control
board checks the float switch. If the float switch is closed, the unit cycles to harvest. If
closed, continue to step 4. If the float switch is open, the unit repeats the 1 minute fill
cycle until water enters and the float switch closes (low water safety protection during
initial start up and at the end of each harvest). Diagnosis: If the water valve does not
open, check for no supply voltage at water valve terminals, bad coil, or plugged screen
or external filter (no water flow). If unit fails to start harvest, check for open float switch
or bad 1 minute timer in board.
4) Initial Harvest Cycle – Inlet water valve remains energized, contactor coil energizes to
start the compressor (and fan motor on a remote condenser unit), and the hot gas valve
energizes. The evaporator warms and the thermistor senses 48°F (9°C). The control
board then receives the thermistor's 3.9 kΩ signal and turns operation of harvest over
to the harvest timer. The timer completes counting (1 to 3 minutes). The unit then cycles
to freeze. Diagnosis: Check if compressor is running, hot gas valve is open, water
valve still open. Average harvest cycle at factory setting is 2 to 3 minutes. How long
does initial harvest last? 1.5 minutes after initial harvest begins, touch the compressor
discharge line. Is it hot? If not check refrigerant pressures and compressor operation.
If it is hot, touch the inlet line to the evaporator. Is it hot? If it is hot and the freeze cycle
is not starting, check the harvest timer adjustment, the thermistor for open circuit, the
discharge line temperature, compressor efficiency, and if the hot gas valve is fully open.
5) Freeze Cycle – Compressor remains energized, pump motor, (line valve on remote
condenser unit), and fan motor energize. The inlet water valve and hot gas valve
de-energize. The unit is held in freeze by a 5 minute short cycle protection timer.
After 5 minutes, the freeze cycle operation is transferred to the float switch for
freeze termination. During the first 5 minutes of freeze, confirm that the evaporator
temperature drops. After 7 minutes in freeze, remove the black float switch lead
from the K5 connector. The unit should immediately switch to the pump-out cycle.
Diagnosis: If the evaporator is not cold, check to see if the hot gas valve is still open
or if the expansion valve is not opening properly, if the water valve is continuing to fill
the reservoir, if there are improper unit pressures, an inoperative compressor, or an
inoperative headmaster (C.P.R.) (remote condenser unit only). If the unit remains in
31
freeze with the float switch removed, replace the board.
Note: Normal freeze cycle will last 20 to 40 minutes depending on model and
conditions. Cycle times and pressures should follow performance data provided
in this manual.
6) Pump-Out Cycle (10/20 second pump out) – the compressor remains energized,
the hot gas valve energizes, the fan motor de-energizes, the pump motor stops for
2 seconds and starts in reverse rotation for 10/20 seconds. (This removes contaminants
from the water reservoir through the check valve (drain valve) and down the drain and
allows for a power flush of the float switch.) Check for clear tubing at the check valve
housing and check the unit drain for water flow. Diagnosis: If the pump motor does not
reverse, check the circuit and capacitor. If water does not pump out, remove the check
valve (drain valve) housing and check/clean the valve assembly.
7) Normal Harvest Cycle – same as the initial harvest cycle – Return to step 4.
Note: Unit continues to cycle until bin control is satisfied or power is switched OFF. (The
pump out cycle can be adjusted to occur every cycle, or every 2, 5, or 10 cycles.
The factory default is every 10 cycles.) The unit always restarts at the 1 minute fill
cycle.
B. Diagnostic Charts
1. No Ice Production
Problem
Possible Cause
[1] The icemaker will not a)Power Supply
start.
Remedy
1. OFF position.
1. Move to ON position.
2. Loose connection.
2. Tighten.
3. Bad contacts.
3. Check for continuity and
replace.
4. Voltage too high or too 4. Check and get
low.
recommended voltage.
b)Fuse (Inside fused
disconnect, if any)
1. Blown.
1. Check for short circuit and
replace.
c) Control Switch
1. OFF position.
1. Move to ICE position.
2. Bad contacts.
2. Check for continuity and
replace.
d)Bin Control Thermostat 1. Tripped with bin filled
with ice.
e)High Pressure Control
1. Remove ice.
2. Ambient temperature
too cool.
2. Increase ambient
temperature.
3. Set too warm.
3. See "II.C.3. Controls
and Adjustments, g) Bin
Control."
4. Bulb out of position.
4. Place in position.
5. Bad contacts.
5. Check for continuity and
replace.
1. Bad contacts.
1. Check for continuity and
replace.
2. Dirty air filter or
condenser.
2. Clean.
32
Problem
Possible Cause
Remedy
[1] The icemaker will not e)High Pressure Control
start. (continued)
(continued)
3. Ambient or condenser 3. Reduce temperature.
water temperature too
warm.
4. Refrigerant
overcharged.
4. Recharge.
5. Fan not operating.
(except water-cooled
model)
5. See chart 1.[6]
6. Refrigerant line or
6. Clean and replace drier.
components plugged.
7. Condenser water
7. Check and get
pressure too low or off. recommended pressure.
(water-cooled model
only)
f) Transformer
1. Coil winding opened
or shorted.
1. Replace.
g)Wiring to Control Board 1. Loose connections or 1. Check for continuity and
open.
replace.
h)Thermistor
1. Leads shorted or
1. See "II.C.3. Controls and
opened and high
Adjustments, b) Harvest
temperature or harvest Control."
backup timer safety
operates. (1 beep or 2
beep alarm)
i) Hot Gas Valve
1. Continues to open
in freeze cycle and
freeze timer safety
operates. (3 beep
alarm)
1. Check for hot gas valve
stuck open and replace.
j) Water Supply Line
1. Water supply off and
water supply cycle
does not finish.
1. Check and get
recommended pressure.
2. Condenser water
pressure too low
or off and pressure
control opens and
closes frequently to
finally operate high
temperature safety.
(1 beep alarm)
2. Check and get
recommended pressure.
1. Mesh filter or orifice
gets clogged and
water supply cycle
does not finish.
1. Clean.
2. Coil winding opened.
2. Replace.
k) Inlet Water Valve
3. Wiring to water valve. 3. Check for loose
connection or open, and
replace.
l) Control Board
1. Defective.
33
1. See "II.C.4. Control Board
Check Procedure."
Problem
Possible Cause
[1] The icemaker will not m)Interlock Switch
start. (continued)
(Cleaning Valve)
1. OFF position.
1. Move to ON position.
2. Bad contacts.
2. Check for continuity and
replace.
1. WASH position.
1. Move to ICE position.
2. Bad contacts.
2. Check and replace.
1. Connector
disconnected.
1. Place in position.
2. Leads opened or
defective switch.
2. Check and replace.
3. Float does not move
freely.
3. Clean or replace.
b)Control Board
1. Defective.
1. Replace.
a)Magnetic Contactor
1. Bad contacts.
1. Check for continuity and
replace.
2. Coil winding opened.
2. Replace.
n)Wash Switch
[2] Water continues to
be supplied, and the
icemaker will not
start.
[3] Compressor will
not start or stops
operating.
Remedy
a)Float Switch
b)Start Capacitor or Run 1. Defective.
Capacitor
1. Replace.
c) Internal Overload
1. Loose terminal.
Protector Open (check
1 through 3 to the right 2. Voltage.
and d through f below)
3. Dirty condenser.
1. Tighten or replace.
3. Clean.
d)Starter
1. Bad contacts.
1. Check and replace.
2. Coil winding opened.
2. Replace.
e)Compressor
f) Control Board
2. Check and correct.
1. Wiring to compressor. 1. Check for loose
connection or open, and
replace.
2. Defective.
2. Replace.
3. Protector tripped.
3. Reduce temperature.
1. No power to contactor. 1. See "II.C.4. Control Board
Check Procedure."
[4] Water continues to
a)Inlet Water Valve
be supplied in freeze
cycle.
b)Control Board
1. Diaphragm does not
close.
1. Check for water leaks with
icemaker off.
1. Defective.
1. See "II.C.4. Control Board
Check Procedure."
[5] No water comes from a)Water Supply Line
spray tubes. Water
pump will not start, or
freeze cycle time is
b)Inlet Water Valve
too short.
1. Water pressure too
1. Check and get
low and water level in
recommended pressure.
water tank too low.
c) Water System
1. Dirty mesh filter or
1. Clean.
orifice and water level
in water tank too low.
1. Water leaks.
34
1. Check connections for
water leaks, and replace.
Problem
Possible Cause
[5] No water comes from c) Water System
spray tubes. Water
(continued)
pump will not start, or
freeze cycle time is
too short. (continued) d)Pump Motor
Remedy
2. Clogged.
2. Clean.
3. Pump out check valve 3. Check assembly and
leaking by.
clean.
1. Motor winding opened. 1. Replace.
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
impeller.
5. Replace and clean.
6. Mechanical seal worn 6. Check and replace.
out.
[6] Fan motor will
not start, or is not
operating.
[7] All components
run, but no ice is
produced.
e)Control Board
1. Defective.
1. See "II.C.4. Control Board
Check Procedure."
a)Fan Motor
1. Motor winding opened. 1. Replace.
2. Bearing worn out.
2. Replace.
3. Wiring to fan motor.
3. Check for loose
connection or open, and
replace.
4. Defective capacitor.
4. Replace.
5. Fan blade bound.
5. Check and replace.
b)Control Board
1. Defective.
1. See "II.C.4. Control Board
Check Procedure."
a)Refrigerant
1. Undercharged.
1. Check for leaks and
recharge.
2. Air or moisture
trapped.
2. Replace drier and
recharge.
b)Compressor
1. Defective valve.
1. Replace.
c) Hot Gas Valve
1. Continues to open in
freeze cycle.
1. Check and replace.
d)Line Valve
1. Continues to close in
freeze cycle.
1. Check and replace.
e)Inlet Water Valve
1. Water valve is wide
open during freeze.
1. Check for water leaks with
icemaker off.
f) Headmaster (C.P.R.)
(Remote Unit)
1. Not operating properly 1. Replace headmaster.
and liquid line
temperature too warm.
g)Water Supply Line
(water-cooled model
only)
1. Condenser water
1. Check and get
pressure too low or off
recommended pressure.
and pressure control
opens and closes
frequently.
h)Water Regulator
(water-cooled model
only)
1. Set too high.
35
1. Adjust or replace. See
"V.I. Adjustment of Water
Regulating Valve."
2. Evaporator is Frozen Up
Problem
Possible Cause
[1]Freeze cycle time is
too long.
a) Float Switch
1. Leads short-circuit or
defective switch.
1. Check and replace.
2. Float does not move
freely.
2. Clean or replace.
b) Inlet Water Valve
1. Diaphragm does not
close.
1. Check for water leaks with
icemaker off.
c) Control Board
1. Defective.
1. See "II.C.4. Control Board
Check Procedure."
1. Scaled up.
1. Clean.
1. Water pressure too
low.
1. Check and get
recommended pressure.
1. Dirty/Restricted
1. Replace filter.
1. Dirty mesh filter or
orifice.
1. Clean.
2. Diaphragm does not
close.
2. Check for water leaks with
icemaker off.
e) Ambient and/or water
temperature.
1. Too cool.
1. Increase temperature.
f) Line Valve
1. Continues to open in
harvest cycle.
1. Check operation in harvest
cycle and replace.
g) Thermistor
1. Out of position or
loose attachment.
1. See "V.I. Removal
and Replacement of
Thermistor."
h) Control Board
1. Harvest timer is set
too short.
1. Adjust longer, referring
to "II.C.3. Controls and
Adjustments, c) Harvest
Timer.
2. Defective.
2. See "II.C.4. Control Board
Check Procedure."
1. Clogged.
1. Clean
2. Out of position.
2. Place in position.
b) Water System
1. Dirty.
1. Clean.
c) Refrigerant
1. Undercharged.
1. Check for leaks and
recharge.
d) Expansion Valve
1. Bulb out of position or 1. Place in position.
loose attachment.
[2]All ice formed on
a) Evaporator
evaporator does not b) Water Supply Line
fall into bin in harvest
cycle.
c) Water Filter System
d) Inlet Water Valve
[3]Other
Remedy
a) Spray Tubes
e) Hot Gas Valve
f) Ice Cube Guide
2. Defective.
2. Replace.
1. Coil winding opened.
1. Replace.
2. Plunger does not
move.
2. Replace.
3. Wiring to hot gas
valve.
3. Check for loose
connection or open, and
replace.
1. Out of position and ice 1. Place in position.
trapped.
36
Problem
Possible Cause
Remedy
[3]Other (continued)
g) Water Supply Line
1. Too small; requires
1. Increase water line size.
3/8" OD line dedicated
per machine.
h) Water Filter
1. Flow rate too small.
1. Replace with filter that has
larger flow rate.
3. Low Ice Production
Problem
Possible Cause
Remedy
[1] Freeze cycle time is
long.
a) See chart 1.[3] and check dirty air filter or condenser, ambient or water
temperature, water pressure, condenser water regulating valve (water-cooled
model), and refrigerant charge.
b) See chart 2.[1] and check float switch, inlet water valve and control board.
c) Check pump, hot gas valve, headmaster (C.P.R.) (remote air-cooled model),
expansion valve, refrigeration check valve, and compressor.
[2] Harvest cycle time is a) See chart 2.[2] and check control board, thermistor, evaporator, ambient and/or
long.
water temperature, water supply line, inlet water valve, line valve, and gas valve.
4. Abnormal Ice
Problem
Possible Cause
[1] Small cubes.
a) Ice Cube Guide
Remedy
1. Out of position.
Circulated water falls
into bin.
1. Place in position.
b) See chart 1.[5] and check water supply line, inlet water valve, water system,
pump motor, and control board.
c) Pump Out Check Valve 1. Dirty.
[2] Cloudy or irregular
cubes.
1. Clean.
a) See chart 2.[1] and 2.[3], and check float switch, inlet water valve, control
board, spray tubes, water system, refrigerant charge, and expansion valve.
b) Spray Guide
1. Dirty.
1. Clean.
c) Water Quality
1. High hardness or
contains impurities.
1. Install a water softener or
filter.
5. Other
Problem
Possible Cause
Remedy
[1] Icemaker will not stop a) Bin Control Thermostat 1. Set too cold.
when bin is filled with
2. Defective.
ice.
1. Adjust warmer.
[2] Abnormal noise.
2. Replace
a) Pump Motor
1. Bearings worn out.
1. Replace
b) Fan Motor
1. Bearings worn out.
1. Replace
2. Fan blade deformed.
2. Replace fan blade.
3. Fan blade does not
move freely.
3. Replace.
c) Compressor
1. Bearings worn out or 1. Replace.
cylinder valve broken.
37
Problem
Possible Cause
[2] Abnormal noise.
(continued)
c) Compressor
(continued)
2. Mounting pad out of
position.
2. Reinstall.
d) Refrigerant Lines
1. Rub or touch other
lines or surfaces.
1. Replace.
a) Drain Line(s)
1. Plugged.
1. Clean.
b) Icemaker and Bin
1. Drains not run
separately.
1. Separate the drain lines.
c) Ice Cube Guide
1. Out of position.
Circulated water falls
into bin.
1. Place in position.
[3] Ice in storage bin
often melts.
Remedy
38
V. Removal and Replacement of Components
IMPORTANT
Ensure all components, fasteners and thumbscrews are securely in place after
the equipment is serviced.
IMPORTANT
1. The Polyol Ester (POE) oils used in R-404A units can absorb moisture
quickly. Therefore 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. Do not replace the drier until after all other repair or replacement
has been made.
3. Do not leave the system open for longer than 15 minutes when replacing or
servicing parts.
A. Service for Refrigerant Lines
1. Refrigerant Recovery
The icemaker unit is provided with refrigerant access valves. Using proper refrigerant
practices recover the refrigerant from the access valves and store it in an approved
container. Do not discharge the refrigerant into the atmosphere.
2. Evacuation and Recharge (R-404A)
1) Attach service manifold hoses and a vacuum pump to the system. Be sure to connect
charging hoses to both high and low-side access valves.
IMPORTANT
The vacuum level and vacuum pump may be the same as those for current
refrigerants. However, the rubber hose and gauge manifold to be used for
evacuation and refrigerant charge should be exclusively for POE oils.
2) Turn on the vacuum pump. Never allow the oil in the vacuum pump to flow backward.
3) Allow the vacuum pump to pull down to a 29.9" Hg vacuum. Evacuating period depends
on pump capacity.
4) Close the low-side valve and high-side valve on the service manifold.
5) Disconnect the vacuum pump and attach a refrigerant service cylinder to the high-side
line. Remember to loosen the connection and purge the air from the hose.
For air-cooled and water-cooled models, see the nameplate for the required
refrigerant charge. For remote air-cooled models, see the charge label in the machine
compartment. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant
which meets ARI Standard No. 700-88 be used.
39
6) A liquid charge is recommended for charging an R-404A system. Invert the service
cylinder and place it on scales. Open the high-side, service manifold valve.
7) Allow the system to charge with liquid until the proper charge weight is met.
8) If necessary, add any remaining charge to the system through the low-side. Use a
throttling valve or liquid dispensing device to add the remaining liquid charge through
the low-side access port with the unit running.
9) Close the two refrigerant access valves, and disconnect the service manifold hoses.
10) Cap the access valves to prevent a possible leak.
B. Brazing
DANGER
1. Refrigerant R-404A itself is not flammable at atmospheric pressure and
temperatures up to 176°F (80°C).
2. Refrigerant 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. Always recover the refrigerant and store it in an approved container. Do not
discharge the refrigerant into the atmosphere.
4. Do not use silver alloy or copper alloy containing arsenic.
5. Do not use R-404A as a mixture with pressurized air for leak testing.
Refrigerant leaks can be detected by charging the unit with a little refrigerant,
raising the pressure with nitrogen and using an electronic leak detector.
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 braxe inside the evaporator case, use sandpaper to remove the
coating from the brazing connections before unbrazing the components.
C. Removal and Replacement of Compressor
IMPORTANT
Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repair or replacement has been
made.
Note: When replacing a compressor with a defective winding, be sure to install the
new start capacitor and start relay supplied with the replacement compressor.
Due to the ability of the POE oil in the compressor to absorb moisture quickly,
the compressor must not be opened more than 15 minutes for replacement or
service. Do not mix lubricants of different compressors even if both are charged
with R-404A, except when they use the same lubricant.
1) Turn off the power supply.
40
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the terminal cover on the compressor and disconnect the compressor wiring.
5) Remove the 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.
10) Remove the drier, then place the new drier in position.
11) Remove the plugs from the suction, discharge and process pipes.
12) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
13) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
14) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled
models, see the nameplate for the required refrigerant charge. For remote air-cooled
models, see the charge label in the machine compartment.
15) Connect the terminals and replace the terminal cover in its correct position.
16) Replace the panels in their correct positions.
17) Turn on the power supply.
D. Removal and Replacement of Drier
IMPORTANT
Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repair or replacement has been
made.
1) Turn off the power supply.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the drier, then place the new drier in position. Install the new drier with the
arrow on the drier in the direction of the refrigerant flow.
5) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
6) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
7) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled
models, see the nameplate for the required refrigerant charge. For remote air-cooled
models, see the charge label in the machine compartment.
8) Replace the panels in their correct positions.
9) Turn on the power supply.
41
E. Removal and Replacement of Expansion Valve
IMPORTANT
Sometimes moisture in the refrigeration circuit exceeds the drier capacity and
freezes up at the expansion valve. Always install a new drier every time the
sealed refrigeration system is opened. Do not replace the drier until after all
other repair or replacement has been made.
1) Turn off the power supply.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the insulation and the expansion valve bulb on the suction line.
5) Remove the expansion valve cover and disconnect the expansion valve. Place the new
expansion valve in position.
6) Remove the drier, then place the new drier in position.
7) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
WARNING
Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 250°F (121°C).
8) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
9) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled
models, see the nameplate for the required refrigerant charge. For remote air-cooled
models, see the charge label in the machine compartment.
10) Attach the expansion valve bulb to the suction line in the same location as the previous
bulb. The bulb should be at the 12 o'clock position on the tube. Be sure to secure the
bulb with the clamp and holder and to insulate it.
11) Place the expansion valve cover in position.
12) Replace the panels in their correct positions.
13) Turn on the power supply.
42
F. Removal and Replacement of Hot Gas Valve and Line Valve
IMPORTANT
1. Always use a copper tube of the same diameter and length when replacing
the hot gas lines; otherwise the performance may be reduced.
2. Always install a new drier every time the sealed refrigeration system is
opened. Do not replace the drier until after all other repair or replacement
has been made.
3. Always replace the strainer when replacing the hot gas valve.
1) Turn off the power supply.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the screw and the solenoid.
5) Disconnect the hot gas valve or line valve. Remove the strainer.
6) Place the new valve and strainer 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.
CAUTION
Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 250°F (121°C).
9) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
10) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled
models, see the nameplate for the required refrigerant charge. For remote air-cooled
models, see the charge label in the machine compartment.
11) Cut the leads of the solenoid allowing enough lead length to reconnect using closed
end connectors.
12) Connect the new solenoid leads.
13) Attach the solenoid to the valve body and secure it with a screw.
14) Replace the panels in their correct positions.
15) Turn on the power supply.
43
G. Removal and Replacement of Evaporator
IMPORTANT
Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repairs or replacement have been
made.
1) Turn off the power supply.
2) Remove the panels and the top insulation over the evaporator.
3) Recover the refrigerant and store it in an approved container.
4) Remove the spray tubes and the insulations at the "U" shaped notch where the
refrigeration tubings pass through the molded chassis.
5) Disconnect the evaporator tubing.
6) Remove the pop rivets securing the evaporator, 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) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
11) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled
models, see the nameplate for the required refrigerant charge. For remote air-cooled
models, see the charge label in the machine compartment.
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.
H. Removal and Replacement of Water Regulating Valve Water Cooled Model Only
IMPORTANT
Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repair or replacement has been
made.
1) Turn off the power supply.
2) Close the water supply line shut-off valve.
3) Remove the panels.
4) Recover the refrigerant and store it in an approved container.
5) Disconnect the capillary tube at the condenser outlet.
6) Disconnect the flare-connections of the valve.
44
7) Remove the screws and the valve from the bracket.
8) Install the new valve.
9) Remove the drier, 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) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
12) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
13) Connect the flare-connections.
14) Open the water supply line shut-off valve.
15) Check for water leaks.
16) Replace the panels in their correct positions.
17) Turn on the power supply.
I. Adjustment of Water Regulating Valve - Water-Cooled Model Only
The water regulating valve (also called "water regulator") is factory-adjusted. No adjustment
is required under normal use. Adjust the water regulator, if necessary, using the following
procedures.
1) Prepare a thermometer to check the condenser drain temperature. Attach a pressure
gauge to the high-side line of the system.
2) Five minutes after a freeze cycle starts, confirm that the thermometer reads 104°F to
115°F (40°C to 46°C). If it does not, rotate the adjustment screw by using a flat blade
screwdriver until the temperature is in the proper range. See Fig. 1. Next, check that
the reference pressure is in the range indicated in the Head Pressure table in the
Performance Data section. If it is not in the proper range, verify the refrigerant charge.
3) Check that the condenser drain temperature is stable.
Adjustment
Screw
CW – Higher
CCW – Lower
Top View
Fig. 1
45
J. Removal and Replacement of Headmaster (Condensing Pressure
Regulator - C.P.R.) - Remote Air-Cooled Model Only
IMPORTANT
Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repair or replacement has been
made.
1) 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.
8) Braze all fittings with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
CAUTION
Always protect the headmaster body by using a damp cloth to prevent it from
overheating. Do not braze with the headmaster body exceeding 250°F (121°C).
9) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
10) Evacuate the system and charge it with refrigerant. See the charge label in the machine
compartment for the required refrigerant charge.
11) Replace the panels in their correct positions.
12) Turn on the power supply.
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K. Removal and Replacement of Thermistor
IMPORTANT
1. Fragile, handle very carefully.
2. Always use a recommended sealant (High Thermal Conductive Type), Model
KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y00011, or Part Code 4A0683-01 equivalent.
3. Always use a recommended foam insulation (Non-absorbent Type) or
equivalent.
4. Do not shorten or cut the thermistor leads when installing.
1) Turn off the power supply.
Thermistor Lead
2) Remove the panels.
Cable Tie
3) Remove the control box cover.
4) Disconnect the thermistor leads from the
K3 connector on the control board.
5) Remove the plastic cable ties, foam
insulation, thermistor holder and
thermistor. See Fig. 2.
6) Scrape away the old sealant on the
thermistor holder and the suction pipe.
Foam Insulation
7) Wipe off moisture or condensation on the
suction pipe.
Fig. 2
Thermistor Holder
8) Smoothly apply recommended sealant (KE4560RTV, Part Code 60Y000-11 or
4A0683‑01) to the thermistor holder concave.
9) Attach the new thermistor to the suction pipe in the same position as the previous
thermistor. Be very careful to prevent damage to the leads. Secure it using the
thermistor holder and recommended foam insulation.
10) Secure the insulation using the plastic cable ties.
11) Connect the thermistor leads through the bushing of the control box to the K3
connector on the control board.
Note: Do not cut the leads of the thermistor while installing it.
12) Replace the control box cover and the panels in their correct positions.
13) Turn on the power supply.
L. Removal and Replacement of Fan Motor
Note: When replacing a fan motor with defective winding, it is recommended that a new
capacitor be installed.
1) Turn off the power supply.
2) Remove the panels.
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3) Remove the junction box cover from the remote condenser unit (remote air-cooled
model).
4) Remove the closed end connectors from the fan motor leads.
5) Remove the fan motor bracket and fan motor.
6) Install the new fan motor and replace the removed parts in the reverse order of which
they were removed.
7) Replace the panels in their correct positions.
8) Replace the junction box cover in its correct position (remote air-cooled model).
9) Turn on the power supply.
M. Removal and Replacement of Inlet Water Valve
1) Turn off the power supply.
2) Close the water supply line shut-off valve.
3) Remove the front panel.
4) Remove the valve outlet tubing by releasing the clamp.
5) Loosen the fitting nut. Be careful not to lose the washer.
6) Disconnect the terminals from the water valve.
7) Remove bracket and valve from the unit.
8) Remove the valve from the bracket. Attach new valve to the bracket, then install the
valve.
9) Replace the removed parts in the reverse order of which they were removed. Make sure
the washer is in place in the fitting nut.
10) Open the water supply line shut-off valve.
11) Turn on the power supply.
12) Check for leaks.
13) 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) Remove the base cover.
4) Drain the water tank by removing one end
of the pump tubing. See Fig. 3.
5) Replace the removed parts in their correct positions.
6) Disconnect the pump suction and discharge hoses.
7) Remove the closed end connectors from the pump motor leads.
Fig. 3
8) Remove the screw attaching the pump motor assembly to the base, then remove the
pump motor assembly.
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9) Remove the screw attaching the pump motor to the pump motor bracket.
10) Remove the screws attaching the pump housing to the pump motor. Remove the
housing and check the impeller.
11) If the impeller is defective, install a new impeller.
12) Install the new motor or new parts, and replace the removed parts in the reverse order
of which they were removed.
13) Turn on the power supply and check for leaks.
14) Replace the base cover in its correct position.
15) Replace the front panel in its correct position.
O. Removal and Replacement of Spray Tubes
1) Turn off the power supply.
2) Remove the front panel and the insulation panel.
3) Remove the rubber hoses from the spray tubes (water supply pipe).
4) Release the clamps and disconnect the rubber hoses.
5) Remove the spray tubes.
6) Install the new spray tubes, and replace the removed parts in the reverse order of which
they were removed.
7) Replace the panels in their correct positions.
8) Turn on the power supply.
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VI. Cleaning and Maintenance Instructions
IMPORTANT
Ensure all components, fasteners and thumbscrews are securely in place after
any maintenance or cleaning is done to the equipment.
A. Cleaning and Sanitizing Procedures
WARNING
1. HOSHIZAKI recommends cleaning this unit at least once a year. More
frequent cleaning, however, may be required in some existing water
conditions.
2. To prevent injury to individuals and damage to the icemaker, do not use
ammonia type cleaners.
3. Always wear liquid-proof gloves to prevent the cleaning and sanitizing
solutions from coming into contact with skin.
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.
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1. Cleaning Procedure
1) Dilute approximately 16 fl. oz. of the recommended cleaner Hoshizaki "Scale Away" or
"LIME-A-WAY" (Economics Laboratory, Inc.) with 3 gal. (11 l) of water.
2) Remove all ice from the evaporator and the storage bin.
Note: To remove cubes on the evaporator, turn off the power supply and turn it on
after 3 minutes. The harvest cycle starts and the cubes will be removed from the
evaporator.
3) Turn off the power supply.
4) Remove the front panel and the base
cover, and then remove the insulation
panel by lifting up the panel slightly and
pulling it towards you.
5) Remove one end of the pump tubing (see
Fig. 4). Drain the water tank. Replace the
pump tubing in its correct position.
Fig. 4
6) In bad or severe water conditions, clean the float switch assembly as described below.
Otherwise, continue to step 7.
a. 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. Wipe the inside of the rubber boot with cleaning solution.
d. Reassemble the float switch assembly and replace it and the rubber boot in their
correct positions.
7) Pour the cleaning solution into the water tank.
8) Fully open the cleaning valve on the left side wall of the machine compartment.
9) Move the control switch on the control box to the "WASH" position.
10) Replace the insulation panel and the front panel in their correct positions.
11) Turn on the power supply and start the washing process.
12) Turn off the power supply after 30 minutes.
13) Remove the front panel.
14) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in
its correct position.
15) Move the control switch to the "ICE" position.
16) Close the cleaning valve.
Note: The icemaker will not operate unless the cleaning valve is completely closed.
17) Replace the front panel in its correct position.
18) Turn on the power supply to fill the water tank with water.
19) Turn off the power supply after 3 minutes.
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20) Remove the front panel and fully open the cleaning valve.
21) Move the control switch to the "WASH" position.
22) Replace the front panel in its correct position.
23) Turn on the power supply to rinse off the cleaning solution.
24) Turn off the power supply after 5 minutes.
25) Remove the front panel.
26) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in
its correct position.
27) Repeat steps 15 through 26 three more times to rinse thoroughly.
Note: If you do not sanitize the icemaker, go to step 10 in "2. Sanitizing Procedure."
2. Sanitizing Procedure - Following Cleaning Procedure
1) Dilute a 5.25% sodium hypochlorite solution (chlorine bleach) with water (add 1.5 fl. oz.
of sanitizer to 3 gal. of water).
2) Remove the insulation panel.
3) Pour the sanitizing solution into the water tank.
4) Replace the insulation panel and the front panel in their correct positions.
Note: Make sure that the control switch is in the "WASH" position and the cleaning valve
is open.
5) Turn on the power supply, and start the sanitizing process.
6) Turn off the power supply after 15 minutes.
7) Remove the front panel.
8) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in
its correct position.
9) Repeat steps 15 through 26 in "1. Cleaning Procedure" two times to rinse thoroughly.
10) Close the cleaning valve.
11) Move the control switch to the "ICE" position.
12) Replace the front panel and the base cover in their correct positions.
13) Clean the storage bin with water.
14) Turn on the power supply, and start the automatic icemaking process.
B. Maintenance
IMPORTANT
This icemaker must be maintained individually, referring to the instruction
manual and labels provided with the icemaker.
1. Stainless Steel Exterior
To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth. Use a
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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 bin.
• Keep the scoop clean. Clean it by using a neutral cleaner and rinse thoroughly.
• Clean the bin liner by using a neutral cleaner. Rinse thoroughly after cleaning.
3. Air Filters (air-cooled models only)
The plastic mesh air filters located behind the louvers remove dirt or dust from the air,
and keep the condenser from getting clogged. As the filters get clogged, the icemaker’s
performance will be reduced. Check the filters at least twice a month. When they are
clogged, use warm water and a neutral cleaner to wash the filters.
4. Condenser (air-cooled and remote air-cooled models only)
Check the condenser once a year, and clean if required by using a brush or vacuum
cleaner. More frequent cleaning may be required depending on the location of the
icemaker or condenser unit.
C. Preparing the Icemaker for Long Storage
WARNING
When shutting off the icemaker for an extended time, drain out all water from
the water tank and remove the ice from the storage bin. The storage bin should
be cleaned and dried. Drain the icemaker to prevent damage to the water
supply line at subfreezing temperatures, using air or carbon dioxide. Shut off
the icemaker until the proper ambient temperature is resumed.
When the icemaker is not used for two or three days, it is sufficient to only move the control
switch to the "OFF" position, unless the icemaker will be at subfreezing temperatures.
1. On water-cooled model only, first remove the water from the water-cooled
condenser:
1) Remove the front panel.
2) Move the control switch on the control box to the "OFF" position.
3) Wait 3 minutes.
4) Move the control switch to the "ICE" position.
5) Allow 5 minutes for the icemaker to fill with water and the water pump to start operating.
6) Close the water-cooled condenser water supply line shut-off valve.
7) Open the drain valve for the water-cooled condenser water supply line.
8) Allow the line to drain by gravity.
9) Quickly attach compressed air or carbon dioxide supply to the condenser water line
drain valve.
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10) Blow the water-cooled condenser out, using compressed air or carbon dioxide until
water stops coming out.
2. Drain the potable water supply line:
1) Remove the front panel.
2) Move the control switch on the control box to the "OFF" position.
3) Wait 3 minutes.
4) Close the potable water supply line shut-off valve and open the potable water supply
line drain valve.
5) Allow the line to drain by gravity.
6) Attach compressed air or carbon dioxide supply to the potable water line drain valve.
7) Move the control switch to the "ICE" position.
8) Blow the potable water line out using compressed air or carbon dioxide.
3. Drain the potable water tank:
1) Turn off the power supply.
2) Move the control switch to the "OFF" position.
3) Remove the front panel and the base
cover, and then remove the insulation
panel by lifting up the panel slightly and
pulling it towards you.
5) Remove one end of the pump tubing (see
Fig. 5). Drain the water tank. Replace the
pump tubing in its correct position.
Fig. 5
5) Remove all ice from the storage bin, and
clean the storage bin.
7) Replace the front panel in its correct position.
8) Close the drain valve.
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