Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber Models

Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber Models
Hoshizaki
Hoshizaki America, Inc.
Modular Crescent Cuber
Models
KM-320MAH-E
KM-515MAH-E
KM-650MAH-E
“A Superior Degree
of Reliability”
SERVICE MANUAL
www.hoshizaki.com
™
89/336
73/23
Number: 73170
Issued: 11-13-2008
IMPORTANT
Only qualified service technicians should attempt to install, service, or maintain
this 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, 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 the appropriate
Hoshizaki Service Office:
UK/Ireland - Hoshizaki UK
TEL : +44 (0)845 456 0585
FAX: +44 (0)1462 499080
Holland - Hoshizaki Europe
TEL : +31 (0)20 6918499
FAX: +31 (0)20 6918768
Belgium/Luxemburg - Hoshizaki Belgium
TEL : +32 (0)2 7123030
FAX: +32 (0)2 7123031
Germany/Switzerland/Austria - Hoshizaki Deutschland
TEL : +49 (0)2154 92810
FAX: +49 (0)2154 928128
France - Hoshizaki France
TEL : +33 (0)1 48639380
FAX: +33 (0)1 48639388
Other countries - Hoshizaki Europe
TEL: +31 (0)20 6918499
FAX: +31 (0)20 6918768
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 manual 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
I. Specifications...................................................................................................................... 5
A. KM-320MAH-E (self-contained air-cooled).................................................................... 5
B. KM-515MAH-E (self-contained air-cooled).................................................................... 6
C. KM-650MAH-E (self-contained air-cooled).................................................................... 7
II. General Information............................................................................................................ 8
A. Dimensions / Connections............................................................................................. 8
1. KM-320MAH-E (self-contained air-cooled)............................................................... 8
2. KM-515MAH-E (self-contained air-cooled)............................................................... 9
3. KM-650MAH-E (self-contained air-cooled)............................................................. 10
B. Construction................................................................................................................. 11
1. KM-320MAH-E (self-contained air-cooled)............................................................. 11
2. KM-515MAH-E (self-contained air-cooled)............................................................. 12
3. KM-650MAH-E (self-contained air-cooled)............................................................. 13
C. Sequence of Operation................................................................................................ 14
1. One Minute Fill Cycle............................................................................................. 14
2. Initial Harvest Cycle .............................................................................................. 14
3. Freeze Cycle ......................................................................................................... 14
4. Pump-Out Cycle .................................................................................................... 14
5. Normal Harvest Cycle ........................................................................................... 15
D. Control Board.............................................................................................................. 17
1. Control Board Layout............................................................................................. 18
2. Features................................................................................................................. 19
a) Maximum Water Supply Period – 6 minutes....................................................... 19
b) Harvest Backup Timer and Freeze Timer........................................................... 19
c) High Temperature Safety.................................................................................... 19
d) Low Water Safety................................................................................................ 19
e) High Voltage and Low Voltage Cut-outs............................................................. 19
f) LED Lights and Audible Alarm Safeties............................................................... 20
3. Controls and Adjustments...................................................................................... 21
a) Default Dip Switch Settings................................................................................. 21
b) Harvest Timer (S4 dip switch 1 & 2).................................................................... 21
c) Pump-Out Timer (S4 dip switch 3 & 4)................................................................ 22
d) Pump-Out Frequency Control (S4 dip switch 5 & 6)........................................... 23
e) Factory Use (S4 dip switch 7 & 8)....................................................................... 23
f) Freeze Timer (S4 dip switch 9 & 10).................................................................... 23
4. Control Board Check Procedure............................................................................ 24
5. Control Board Replacement................................................................................... 24
E. Harvest Control – Thermistor....................................................................................... 24
1. Thermistor Check................................................................................................... 24
F. Float Switch................................................................................................................. 25
1. Float Switch Check................................................................................................. 25
2. Float Switch Cleaning............................................................................................. 26
G. Bin Control................................................................................................................... 26
III. Technical Information...................................................................................................... 27
A. Water Circuit and Refrigeration Circuit........................................................................ 27
B. Wiring Diagram............................................................................................................ 28
1. KM-320MAH-E (self-contained air-cooled)............................................................. 28
2. KM-515MAH-E (self-contained air-cooled)............................................................. 29
3. KM-650MAH-E (self-contained air-cooled)............................................................. 30
C. Performance Data....................................................................................................... 31
1. KM-320MAH-E (self-contained air-cooled)............................................................. 31
2. KM-515MAH-E (self-contained air-cooled)............................................................. 32
3. KM-650MAH-E (self-contained air-cooled)............................................................. 33
IV. Service Diagnosis........................................................................................................... 34
A. 10-Minute Diagnostic Procedure ................................................................................ 34
B. Diagnostic Charts........................................................................................................ 36
1. No Ice Production................................................................................................... 36
2. Evaporator is Frozen Up........................................................................................ 39
3. Low Ice Production................................................................................................. 40
4. Abnormal Ice.......................................................................................................... 41
5. Other...................................................................................................................... 42
V. Removal and Replacement of Components.................................................................... 43
A. Service for Refrigerant Lines....................................................................................... 43
1. Refrigerant Recovery............................................................................................. 43
2. Brazing................................................................................................................... 43
3. Evacuation and Recharge (R-404A)...................................................................... 44
B. Removal and Replacement of Compressor................................................................. 45
C. Removal and Replacement of Expansion Valve......................................................... 46
D. Removal and Replacement of Hot Gas Valve or Liquid Line Valve............................ 47
E. Removal and Replacement of Evaporator................................................................... 48
F. Removal and Replacement of Condenser................................................................... 49
G. Removal and Replacement of Thermistor................................................................... 50
H. Removal and Replacement of Fan Motor.................................................................... 51
I. Removal and Replacement of Inlet Water Valve.......................................................... 51
J. Removal and Replacement of Pump Motor................................................................. 52
VI. Cleaning and Maintenance ............................................................................................ 53
A. Cleaning and Sanitizing Instructions............................................................................ 53
1. Cleaning Procedure................................................................................................ 53
2. Sanitizing Procedure - Following Cleaning Procedure........................................... 54
B. Maintenance................................................................................................................ 56
C. Preparing the Icemaker for Long Storage................................................................... 56
I. Specifications
A. KM-320MAH-E (self-contained air-cooled)
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day ( kg/day )
Reference without *marks
FOR THE EUROPEAN MARKET
ICE CAPACITY lbs./day (kg/day)
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
220-240/50/1
3.5 A ( 5 Min. Freeze AT 109°F / WT 59°F)
15 A
15 A
Ambient
WATER TEMP. (°F)
Temp.(°F)
50
70
70
*293 (133)
275 (125)
80
279 (127)
252 (114)
90
275 (125)
*232 (105)
100
273 (124)
228 (103)
10/10°C
346 (157)
20/15°C
303 (137)
90
255 (116)
234 (106)
213 (97)
196 (89)
30/25°C
236 (107)
Crescent Cube
8 lbs. (3.6 kg) 360pcs.
N/A
90/70°F
70/50°F
710(7.3)
650(5.3)
52(22.2)
117(40.1)
22" x 27-3/8" x 30-5/16" (560 x 695 x 770 mm)
Stainless Steel, Galvanized Steel (Rear)
Net 153 lbs. (69 kg), Shipping 175 lbs. (79 kg)
Cord - 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 ASE32C3E-CAZ-254
Air-Cooled , Fin and tube type
Vertical type, Stainless Steel and Copper
Thermostatic Expansion Valve
R404A, 1 lb. 4.3 oz. (575g)
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
198 - 254 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. KM-515MAH-E (self-contained air-cooled)
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day ( kg/day )
Reference without *marks
FOR THE EUROPEAN MARKET
ICE CAPACITY
lbs./day ( kg/day )
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
220-240/50/1
7.14 A ( 5 Min. Freeze AT 109°F / WT 59°F)
15A
15 A
Ambient
WATER TEMP. (°F)
Temp.(°F)
50
70
70
*513 (233)
482 (219)
80
490 (222)
442 (200)
90
482 (219)
*408 (185)
100
474 (215)
398 (181)
10/10°C
582 (264)
21/15°C
528 (239)
90
441 (200)
401 (182)
366 (166)
328 (149)
30/25°C
406 (184)
Crescent Cube
10.2 lbs. (4.6 kg) 480pcs.
N/A
90/70°F
70/50°F
1200(7.1)
1080(5.1)
108(26.5)
159(31.1)
22" x 27-3/8" x 30-5/16" (560 x 695 x 770 mm)
Stainless Steel, Galvanized Steel (Rear)
Net 151 lbs. (68 kg), Shipping 175 lbs. (79 kg)
Cord - 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 RST64C1E-CAZ-202
Air-Cooled , Fin and tube type
Vertical type, Stainless Steel and Copper
Thermostatic Expansion Valve
R404A, 1 lb. 2.5 oz. (525g)
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
198 - 254 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.
C. KM-650MAH-E (self-contained air-cooled)
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day ( kg/day )
Reference without *marks
FOR THE EUROPEAN MARKET
ICE CAPACITY lbs./day (kg/day)
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
220-240/50/1
6.8 A ( 5 Min. Freeze AT 109°F / WT 59°F)
15 A
15 A
Ambient
WATER TEMP. (°F)
Temp.(°F)
50
70
70
*653 (296)
610 (277)
80
620 (281)
554 (251)
90
610 (277)
*507 (230)
100
602 (273)
495 (225)
10/10°C
734 (333)
20/15°C
603 (274)
90
558 (253)
506 (229)
456 (207)
409 (186)
30/25°C
535 (243)
Crescent Cube
14 lbs. (6.4 kg) 720pcs.
N/A
90/70°F
70/50°F
1200(5.7)
1090(4.0)
94(18.5)
162(24.8)
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)
Cord - 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 RST64C1E-CAZ-202
Air-Cooled , Fin and tube type
Vertical type, Stainless Steel and Copper
Thermostatic Expansion Valve
R404A, 1 lb. 6.6 oz. (640g)
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
198 - 254 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.
II. General Information
A. Dimensions / Connections
Bottom View
Front View
Side View
Back View
Unit: inches (mm)
1. KM-320MAH-E (self-contained air-cooled)
Back View
Bottom View
Side View
Front View
Unit: inches (mm)
2. KM-515MAH-E (self-contained air-cooled)
Front View
Bottom View
Side View
Back View
Unit: mm (inches)
3. KM-650MAH-E (self-contained air-cooled)
10
B. Construction
1. KM-320MAH-E (self-contained air-cooled)
Transformer
(230V→115V)
Water Supply Pipe
Spray Tubes
Expansion Valve
Hot Gas Valve
Inlet Water Valve
Strainer
Control Switch
Condenser
Low Side
Access Valve
Evaporator
High Side
Access Valve
High Pressure
Switch
Control Box
Cord with
Fused Plug
(250V, 13A)
Thermistor
Fan Motor
Drier
Float Switch
Water Pump
Bin Control Thermostat Bulb
(Thermostat Body is in Control Box)
Compressor
11
2. KM-515MAH-E (self-contained air-cooled)
Transformer
(230V→115V)
Expansion Valve
Spray Tubes
Water Supply Pipe
Hot Gas Valve
Strainer
Inlet Water Valve
Control Switch
Condenser
Low Side
Access Valve
High Pressure
Switch
Evaporator
High Side
Access Valve
Control Box
Cord with
Fused Plug
(250V, 13A)
Thermistor
Fan Motor
Liquid Line Valve
Drier
Float Switch
Water Pump
Bin Control Thermostat Bulb
(Thermostat Body is in Control Box)
Compressor
12
3. KM-650MAH-E (self-contained air-cooled)
Transformer
(230V→115V)
Water Supply Pipe
Spray Tubes
High Pressure
Switch
Inlet Water Valve
Condenser
Evaporator
Hot Gas Valve
Cord with
Fused Plug
(250V, 13A)
Control Box
Control Switch
Low Side
Access Valve
Strainer
Expansion Valve
Fan Motor
Thermistor
Drier
Float Switch
Water Pump
High Side
Access Valve
Compressor
Bin Control Thermostat Bulb
(Thermostat Body is in Control Box)
13
C. Sequence of Operation
The steps in the sequence are as outlined below. When power is supplied, the red
"POWER OK" LED on the control board comes on. A 5-second delay occurs at startup.
Note that the order of the LEDs from the outer edge of the control 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 control 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 PM.
2. Initial Harvest Cycle
LEDs 1, 4, and 2 are on. WV remains open, Comp and HGV energize. The control board
monitors the warming of the evaporator via the thermistor located on the suction line.
When the thermistor reaches 48°F (9°C), the control board reads a 3.9 kΩ signal from
the thermistor and turns harvest termination over to the adjustable harvest timer (S4 dip
switch 1 & 2) which is factory set for normal conditions. The harvest timer has settings
of 60, 90, 120, and 180 seconds. For details, see "II.D.3.b) Harvest Timer (S4 dip switch
1 & 2)." When the harvest timer completes its countdown, the harvest cycle is complete
and the freeze cycle starts. The minimum total time allowed by the control board 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. At the end of harvest, the control
board checks the position of F/S and proceeds to the freeze cycle if it is closed or calls
for a 1-minute fill if it is open.
3. Freeze Cycle
LED 1 is on. Comp continues 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 continues to run, HGV opens, LLV closes, and FMS
de‑energizes. PM stops for 15 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 F/S. When the pump-out timer (S4 dip switch 3 & 4) stops counting,
the pump out is complete. The 1st pump out occurs after the 1st freeze cycle. The pumpout frequency control (S4 dip switch 5 & 6) determines the frequency of subsequent
pump outs. For details, see "II.D.3.d) Pump-Out Frequency Control (S4 dip switch 5 &
6)."
14
5. Normal Harvest Cycle
LEDs 1, 4, and 2 are on. Comp and HGV remain energized. PM stops and WV
energizes. The control board monitors the warming of the evaporator via the thermistor
located on the suction line. When the thermistor reaches 48°F (9°C), the control board
reads a 3.9 kΩ signal from the thermistor and turns harvest termination over to the
adjustable harvest timer (S4 dip switch 1 & 2) on cycles with a pump-out and to the
pump-out timer's harvest timer on cycles with a pump out. For details, see "II.D.3.b)
Harvest Timer (S4 Dip Switch 1 & 2)" and "II.D.3.c) Pump-Out Timer." When the harvest
timer completes its countdown, the harvest cycle is complete and the freeze cycle starts.
The minimum total time allowed by the control board 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. At the end of harvest, the control board checks the
position of F/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute fill if
it is open.
Legend: Comp–compressor; FMS–self-contained fan motor; F/S–float switch;
HGV–hot gas valve; LLV–liquid line valve; PM–pump motor; WV–inlet water valve
15
16
WV continues (or
energized)
Comp energized
HGV energized
F/S closed
Thermistor in
control
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
Freeze cycle
operation turned
over to F/S
F/S in
control
PM de-energized for
15 sec., then energized
in reverse for 10/20 sec.
each 1, 2, 5, or 10 cycles.
Comp continues
HGV energized
WV energized (dependent
on pump-out timer setting)
FMS de-energized
LLV de-energized
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. The cleaner and sanitizer flow over the outside of
the evaporator plate assembly.
Comp continues
FMS energized
LLV energized
PM energized
HGV de-energized
WV de-energized
F/S closed
5 minute timer
in control
• Minimum freeze time: 5 minutes
4. Pump-Out
• Maximum freeze time: freeze timer setting
Cycle
3. Freeze Cycle
Components Energized when the Control Switch is in the "WASH" Position
If F/S is open, compressor stops and cycle returns to 1 minute fill
F/S open
WV energized
F/S check
Legend:
Comp-compressor
FMS-self-contained fan motor
F/S-float switch
HGV-hot gas valve
LLV-liquid line valve
PM-pump motor
WV-inlet water valve
Initial startup always
begins here. There
is a 5 second delay
from power on.
1. One Minute
Fill Cycle
2. Harvest Cycle
KM-320MAH-E, KM-515MAH-E, KM-650MAH-E Sequence Flow Chart and Component Operation
D. Control Board
• A Hoshizaki exclusive solid-state control board is employed in KM-320MAH-E,
KM‑515MAH‑E, and KM-650MAH-E Modular Crescent Cubers.
• All models are pretested and factory-adjusted.
CAUTION
1. 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.
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.
17
1. Control Board Layout
Control Products "E" Control Board
"ALARM RESET" Switch
"OUTPUT TEST" Switch
(used to test relays on board)
S4 Dip Switch
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
LED 2
Hot Gas Valve (HGV)
Liquid Line Valve
(LLV) & SelfContained Fan Motor
(FMS) (LLV & FMS
off when LED on)
Connector K1
Pins #1 through #10
#1, 9 Magnetic Contactor
#2 Hot Gas Valve
#3 Liquid Line Valve
Self-Contained Fan Motor
#4 Pump Motor (icemaking)
#5 Pump Motor (pump out)
#6 Inlet Water Valve
#7, 10 Power Supply
#8 Open
LED 3
Pump Motor (PM)
(on at pump out only)
Switch for "C" board
and "ALPINE" board
(service board only)
Set to "ALP" for units
covered in this manual.
LED 4
Inlet Water Valve (WV)
LED 1
Compressor (Comp)
Control Transformer Connector
Control Board
Part Number 2A1410-01 (factory); 2A1410-02 (service)
Type
HOS-001A (Control Products - 10 Pin)
18
2. Features
a) Maximum Water Supply Period – 6 minutes
The inlet water valve will be open 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 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 S4 dip
switch 9 & 10. For details, see "II.D.3.f) Freeze Timer (S4 dip switch 9 & 10)."
The "ALARM 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 control board reads a
.804 kΩ signal from the thermistor and 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 "ALARM
RESET" button on the control board must be pressed with power on to reset the safety.
d) Low Water Safety
The control board checks the position of the float switch at the end of the initial 1 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 1 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.
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.
19
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 beep occurs when the power 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.C. Sequence of Operation."
Time LEDs are On
Energized
Sequence Step
LED
Components
Min.
Max.
Avg.
1 Minute Fill Cycle 4
WV
60 seconds
Harvest Cycle
1, 4, and 2 WV, HGV, 2 minutes 20 minutes 3 to 5 minutes
Comp
Freeze Cycle
1
Comp, PM, 5 minutes freeze timer 30 to 35 minutes
FMS, LLV
setting
Pump-Out Cycle
1, 4*, 3, and Comp, HGV, 10 seconds 20 seconds *pump-out timer
2
PM, WV*
setting
The built in safeties shut down the unit and have alarms as listed below.
No. of Beeps
Type of Alarm
Notes
(every 3 sec.)
1
High Evaporator Temp.
Check for harvest problem (stuck HGV or
(temperature > 127°F)
relay), hot water entering unit, or shorted
(53°C)
thermistor.
2
Harvest Backup Timer
Orange LED marked H TIMER lights up.
(harvest > 20 min. for two Check for open thermistor, HGV not opening,
cycles in a row)
TXV or LLV leaking by, low charge, or
inefficient Comp.
3
Freeze Timer
Yellow LED marked F TIMER lights up. Check
(freeze > specified setting for F/S stuck closed (up), WV leaking by, HGV
for two cycles in a row)
leaking by, PM not pumping, TXV not feeding
Timer is factory set using properly, LLV not opening, low charge, or
S4 dip switch 9 & 10
inefficient Comp.
To reset the above safeties, press the "ALARM RESET" button with the power supply on.
6
Low Voltage
Red LED will turn off if voltage protection
(92Vac ±5% or less)
operates.
The control voltage safeties automatically reset
7
High Voltage
when voltage is corrected.
(147Vac ±5% or more)
Legend: Comp–compressor; FMS–self-contained fan motor; F/S–float switch;
HGV–hot gas valve; LLV–liquid line valve; PM–pump motor; TXV–thermostatic expansion valve; WV–inlet water valve
20
3. 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 your
Hoshizaki Service Office.
a) Default Dip Switch Settings
The dip switches are factory-adjusted to the following positions:
S4 Dip Switch No.
1
2
3
4
5
ON
6
7
8
9
ON OFF OFF ON
10
KM-320MAH-E
ON OFF OFF ON
ON
KM-515MAH-E
OFF OFF OFF OFF OFF OFF OFF OFF ON OFF
KM-650MAH-E
OFF OFF OFF OFF OFF OFF OFF OFF ON
ON
Freeze Timer (9 & 10)
Normally off (7 & 8)
Pump-Out Frequency Control (5 & 6)
Do Not Adjust
Pump-Out Timer (3 & 4)
Harvest Timer (1 & 2)
b) Harvest Timer (S4 dip switch 1 & 2)
The harvest timer starts counting when the thermistor reaches 48°F (9°C) at the
evaporator outlet and the control board reads the thermistor's 3.9 kΩ signal. The harvest
timer is factory-adjusted, and 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 your Hoshizaki
Service Office 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's harvest timer (S4 dip switch 3 & 4, T2) acts in place of
the harvest timer during cycles with a pump out. See "II.D.3.c) Pump-Out Timer (S4 dip
switch 3 & 4)." On KM-515MAH-E and KM-650MAH‑E models, the harvest timer is only
relevant during the initial harvest cycle since a pump out occurs every cycle thereafter.
S4 Dip Switch Setting
No. 1
No. 2
Time
(seconds)
OFF
OFF
60
ON
OFF
90
OFF
ON
120
ON
ON
180
21
c) Pump-Out Timer (S4 dip switch 3 & 4)
CAUTION
The pump-out timer is factory-adjusted, and no adjustment is required. On
KM-515MAH-E and KM-650MAH-E models, never adjust the pump-out timer's
harvest timer (T2) for a time frame less than 150 seconds.
The pump-out timer's harvest timer (T2) acts in place of the harvest timer (S4 dip switch
1 & 2) during the pump-out cycle. On KM-320MAH-E model, the pump out occurs once
every 10 cycles. On KM-515MAH-E and KM-650MAH-E models, the pump out occurs
every cycle.
T1 - When the freeze cycle is complete, the pump motor stops for 15 seconds, then the
pump motor re-starts in the opposite direction and the pump-out cycle begins. The pump
motor drains the water tank for the time determined by the pump-out timer (T1).
T2 - The pump-out timer's harvest timer (T2) starts counting when the thermistor reads
48°F (9°C) at the evaporator outlet. Once the 10/20 second pump-out timer (T1) is
complete, the pump motor stops and the inlet water valve energizes. The harvest cycle
continues until the pump-out timer's harvest timer (T2) terminates.
No adjustment is required under normal use, as the pump-out timer's harvest timer (T2)
is adjusted to the suitable setting. 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 your Hoshizaki Service Office for
recommendations. Keep in mind that setting the pump-out timer's harvest timer (T2) to a
longer setting will decrease 24 hour production. On KM‑515MAH‑E and KM-650MAH-E
models, never adjust the timer for a time frame less than 150 seconds.
S4 Dip Switch Setting
Time (seconds)
No. 3
No. 4
T1
T2
Inlet Water
Valve
OFF
OFF
10
150
Closed
ON
OFF
10
180
Closed
OFF
ON
10
120
Open
ON
ON
20
180
Closed
T1: Time to drain the water tank
T2: Harvest timer at pump out
22
d) Pump-Out Frequency Control (S4 dip switch 5 & 6)
CAUTION
On KM-515MAH-E and KM-650MAH-E models, do not adjust. Adjustments to
this setting may adversely affect performance and warranty coverage.
The pump motor drains the water tank at the frequency set by the pump-out frequency
control. On KM-320MAH-E model, the pump-out frequency control is factory-adjusted
to drain the water tank once every 10 cycles, and no adjustment is generally required.
However, where water quality is bad and the icemaker needs a pump out more often, the
pump-out frequency can be adjusted as shown in the table below. On KM-515MAH-E
and KM‑650MAH-E models, the pump-out frequency control is factory-adjusted to drain
the water tank every cycle. Do not adjust.
S4 Dip Switch Setting
Frequency
No. 5
No. 6
OFF
OFF
every cycle
ON
OFF
every 2 cycles
OFF
ON
every 5 cycles
ON
ON
every 10 cycles
e) Factory Use (S4 dip switch 7 & 8)
Factory set for optimum performance. Do not adjust.
f) Freeze Timer (S4 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 the freeze timer, the control board
initiates the harvest cycle. After 2 consecutive timer terminations, the control board shuts
the machine down. In this case, see "IV.B.3. Low Ice Production" for possible solutions.
The freeze timer is factory adjusted and no adjustment is required.
S4 Dip Switch Setting
No. 9
No. 10
Time
(minutes)
OFF
OFF
60
OFF
ON
50
ON
OFF
70
ON
ON
75
23
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 S4 dip switch settings to assure that they are in the factory default position.
2) Move the control switch to the "ICE" position. The red "POWER OK" LED should come
on. If the LED is off, check the control transformer secondary circuit. 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.
If the secondary circuit does not have proper voltage, check the control transformer
primary circuit. Check for 115V at the 10-pin connector. Check the brown wire at pin
#10 to a white neutral wire for 115V. (Always choose a white neutral wire to establish
a good neutral connection when checking voltages.) Check the fuses (control box and
power cord plug) and the main transformer circuit. For additional checks, see "IV.B.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 should be none, 2, 3, 4, 1. Some components (e.g., the compressor)
will cycle during the test. Note that the order of the relays from the outer edge of the
board is 1, 4, 3, 2. After checking the sequence, the unit automatically starts at the
1 minute fill cycle. If the LEDs light in a different sequence, the control board is bad and
should be replaced.
5. Control Board Replacement
Adjust the dip switches to the factory default settings. See "II.D.3.a) Default Dip Switch
Settings." S4 dip switch 8 must remain off.
Set the application switch (service board only) located between relay X3 & X4 to the
"ALP" position.
E. Harvest Control – Thermistor
A thermistor is used as a harvest control sensor. The thermistor's resistance varies
depending on the suction line temperatures. The control board monitors the resistance to
start the harvest timer. No adjustment is required.
1. Thermistor Check
If necessary, check the resistance between thermistor leads, and visually check the
thermistor mounting, located on the suction line next to the evaporator outlet. To check
the resistance between thermistor leads, follow the steps below.
1) Disconnect the white thermistor connector from the K3 connector on the control board.
2) Remove the thermistor. See "V.G. 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 the resistance between thermistor leads. Normal reading is within 4.7 to 6.2 kΩ.
Replace the thermistor if it is outside the normal reading.
24
F. 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.
1. Float Switch Check
To check the float switch, follow the steps below.
1) Remove the front panel.
2) Move the control switch to the "OFF" position, then unplug the unit from the mains
socket.
3) Remove the base cover. Remove the pump tubing from the tank. See Fig. 1. Allow the
water to drain from the tank. Replace the pump tubing and base cover in their correct
positions.
4) Remove the control box cover.
5) Disconnect the black float switch connector from the K5 connector on the control board.
6) Check for continuity across the float switch leads. With the water tank empty, the float
switch should be open. If open, continue to step 7. If closed, follow the steps in "II.
E.2. Float Switch Cleaning." After cleaning the float switch, check it again. Replace if
necessary.
7) Reconnect the black float switch connector, then replace the control box cover.
8) Plug the unit back in, then move the control switch to the "ICE" position. Replace the
front panel in its correct position. 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 9.
9) Remove the front panel.
10) Move the control switch to the "OFF" position, then unplug the unit from the mains
socket.
11) Remove the control box cover.
12) Disconnect the black float switch connector from the K5 connector on the control board.
Pull Out
Pump Tubing
Do not pull out this side.
Fig. 1
25
13) Check for continuity across the float switch leads. 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 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 "II.E.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) Remove the front panel.
2) Move the control switch to the "OFF" position, then unplug the unit from the mains
socket. Remove the base cover. Remove one end of the pump tubing. See Fig. 1.
Allow the water to drain from the tank. Replace the pump tubing and base cover in their
correct positions.
3) Remove the screws securing the float switch to the icemaker. Remove the float switch
from the rubber boot. Remove the rubber boot.
4) Remove the retainer rod from the bottom of the float switch, then remove the float. Be
careful not to bend the retainer rod excessively when removing it.
5) Wipe down the float switch housing, shaft, float, retainer rod, and rubber boot with a
mixture of 1 part of recommended cleaner Hoshizaki "Scale Away" or "LIME‑A‑WAY"
(Economics Laboratory, Inc.) and 25 parts of warm water. Rinse the parts thoroughly
with clean water.
6) Reassemble the float switch. Replace the rubber boot and float switch in their correct
positions and secure with the screws.
7) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
8) Replace the front panel in its correct position.
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.
However, adjustment may sometimes be needed, particularly at higher altitude locations.
Adjust it so that the icemaker stops automatically within 10 seconds after ice contacts
the bin control thermostat bulb.
26
III. Technical Information
A. Water Circuit and Refrigeration Circuit
1. KM-320MAH-E, KM-515MAH-E, and KM-650MAH-E (self-contained air-cooled)
Spray Tubes
Condenser
Inlet Water Valve
Drier
Evaporator
Water Supply
Fan
High Pressure
Switch
Liquid Line Valve
(KM-515MAH-E Only)
Thermistor
Heat
Exchanger
High Side
Access Valve
Suction
Line
Low Side
Access Valve
Strainer
Water Pump
Float Switch
Water
Tank
Discharge Line
Compressor
Freeze
Drain
Pump Out
Expansion Valve
Check Valve
Refrigeration Circuit
Water Circuit
27
Hot Gas
Valve
(Main)
POWER SUPPLY
28
* Pressure Switch
Air-Cooled Model
Cut-out
412±210 PSIG
Cut-in
327±21 PSIG
*
(Control)
Transformer Output
10.5V at 115V
B. Wiring Diagram
1. KM-320MAH-E (self-contained air-cooled)
(Main)
POWER SUPPLY
29
* Pressure Switch
Air-Cooled Model
Cut-out
412±210 PSIG
Cut-in
327±21 PSIG
*
(Control)
Transformer Output
10.5V at 115V
2. KM-515MAH-E (self-contained air-cooled)
(Main)
POWER SUPPLY
30
* Pressure Switch
Air-Cooled Model
Cut-out
412±210 PSIG
Cut-in
327±21 PSIG
*
(Control)
Transformer Output
10.5V at 115V
3. KM-650MAH-E (self-contained air-cooled)
C. Performance Data
1. KM-320MAH-E (self-contained air-cooled)
APPROXIMATE ICE
PRODUCTION PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
gal./day m3/day
FREEZING CYCLE TIME
min.
HARVEST CYCLE TIME
min.
HEAD PRESSURE
PSIG
kg/cm2G
SUCTION PRESSURE
PSIG
kg/cm2G
AMBIENT TEMP.
(ºF/ºC)
70/21
80/27
50/10
90/32
100/38
70/21
80/27
90/32
293
279
133
127
275
273
125
124
WATER TEMP. (ºF/ºC)
70/21
275
125
252
114
232
228
650
663
668
117
103
98
100/38
70/21
80/27
90/32
100/38
70/21
76
80/27
90/32
100/38
116
106
213
196
97
89
673
686
710
668
691
710
663
100/38
70/21
80/27
90/32
105
103
90/32
255
234
710
710
0.44
0.39
0.37
98
73
52
0.29
51
0.37
0.28
0.19
89
73
47
0.19
43
0.34
0.28
0.18
0.16
34
36
37
37
5.8
37
42
47
47
4.9
39
42
47
48
4.5
5.1
4.9
3.9
3.8
2.8
2.8
3.8
2.7
2.5
70/21
80/27
90/32
210
229
235
14.8
16.1
16.5
235
268
295
16.5
18.8
20.7
253
276
308
17.8
19.4
21.7
100/38
233
16.4
298
21.0
320
22.5
70/21
80/27
90/32
56
57
57
3.9
4.0
4.0
57
59
60
4.0
4.1
4.2
58
60
61
4.1
4.2
4.3
100/38
57
4.0
60
4.2
62
4.4
TOTAL HEAT OF REJECTION FROM CONDENSER
5,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
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.
31
2. KM-515MAH-E (self-contained air-cooled)
APPROXIMATE ICE
PRODUCTION PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
gal./day m3/day
FREEZING CYCLE TIME
min.
HARVEST CYCLE TIME
min.
HEAD PRESSURE
PSIG
kg/cm2G
SUCTION PRESSURE
PSIG
kg/cm2G
AMBIENT TEMP.
(ºF/ºC)
70/21
80/27
90/32
100/38
70/21
80/27
90/32
100/38
70/21
80/27
90/32
100/38
70/21
80/27
90/32
100/38
70/21
50/10
513
490
233
222
482
474
219
215
WATER TEMP. (ºF/ºC)
70/21
482
219
442
200
408
398
1080
1107
1115
125
80/27
90/32
100/38
441
401
200
182
366
328
166
149
1150
1189
1231
1115
1161
1200
1207
1118
159
148
144
185
181
90/32
0.60
0.56
0.55
144
125
108
0.47
106
1260
0.55
0.47
0.41
131
115
97
0.40
87
0.50
0.44
0.37
0.33
26
28
28
29
3.4
28
31
33
34
3.2
32
35
37
40
3.2
3.3
3.2
3.1
3.0
2.9
2.9
3.1
2.9
2.9
70/21
80/27
90/32
245
262
267
17.2
18.4
18.8
267
296
320
18.8
20.8
22.5
294
321
346
20.6
22.5
24.3
100/38
271
19.1
326
22.9
370
26.0
70/21
80/27
90/32
50
53
54
3.5
3.8
3.8
54
60
65
3.8
4.2
4.6
57
61
67
4.0
4.3
4.7
100/38
54
3.8
65
4.6
69
4.9
TOTAL HEAT OF REJECTION FROM CONDENSER
10,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
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.
32
3. KM-650MAH-E (self-contained air-cooled)
APPROXIMATE ICE
PRODUCTION PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
gal./day m3/day
FREEZING CYCLE TIME
min.
HARVEST CYCLE TIME
min.
HEAD PRESSURE
PSIG
kg/cm2G
SUCTION PRESSURE
PSIG
kg/cm2G
AMBIENT TEMP.
(ºF/ºC)
70/21
80/27
50/10
90/32
100/38
70/21
80/27
90/32
653
620
296
281
610
602
277
273
WATER TEMP. (ºF/ºC)
70/21
610
277
554
251
507
495
1090
1115
1122
100/38
70/21
80/27
90/32
253
229
456
409
207
186
1122
1165
1200
1164
1205
1242
1210
1130
100/38
70/21
80/27
90/32
100/38
70/21
230
225
90/32
558
506
1280
162
147
142
0.61
0.56
0.54
142
116
94
0.54
0.44
0.36
130
113
87
0.49
0.43
0.33
119
0.45
92
0.35
81
0.31
80/27
90/32
100/38
29
31
32
32
3.9
32
34
37
38
3.6
35
38
40
43
3.5
3.7
3.6
3.3
3.2
2.9
2.9
3.3
2.9
2.9
70/21
80/27
90/32
236
254
259
16.6
17.8
18.2
259
290
315
18.2
20.4
22.1
286
314
341
20.1
22.1
24.0
100/38
263
18.5
321
22.6
365
25.7
70/21
80/27
90/32
53
55
55
3.7
3.8
3.9
55
58
60
3.9
4.1
4.2
58
60
63
4.1
4.2
4.4
100/38
56
3.9
61
4.3
65
4.6
TOTAL HEAT OF REJECTION FROM CONDENSER
9,800 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
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.
33
IV. Service Diagnosis
A. 10-Minute Diagnostic Procedure
The 10 minute check out procedure is basically a sequence check which can be used
at unit start-up or for system diagnosis. Using this check out procedure will allow you
to diagnose electrical system and component failures in approximately 10 minutes
under normal operating conditions of 70°F (21°C) or warmer air and 50°F (10°C) or
warmer water temperatures. Before conducting a 10 minute checkout, check for correct
installation, proper voltage per unit nameplate, and adequate water supply. Check the
S4 dip switch settings to assure that they are in the factory default position. For factory
default settings, see "II.D.3.a) Default Dip Switch Settings." 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) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket. Access the control box.
2) Plug the unit back in, then move the control switch to the "ICE" position. A 5 second
delay occurs. The red "POWER OK" LED on the control board comes on.
3) One Minute Fill Cycle – LED 4 is on. 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 inlet water valve does not open, check for no supply voltage at inlet 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 control board.
4) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. The inlet water valve remains
energized, the contactor coil energizes to start the compressor, and the hot gas valve
energizes. The inlet water valve is open during harvest for a maximum of 6 minutes or
the length of harvest whichever is shorter. 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 harvest timer has settings of
60, 90, 120, and 180 seconds (S4 dip switch 1 & 2). When the harvest timer countdown
is complete, the freeze cycle starts. Diagnosis: Check if compressor is running, hot
gas valve is open, inlet water valve still open, liquid line valve closed. 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.
34
5) Freeze Cycle – LED 1 is on. Compressor remains energized, pump motor, liquid line
valve, 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 the 5 minute
short cycle protection timer terminates, 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 5 minutes in freeze, remove the black float
switch lead from the K5 connector. The unit should switch out of the freeze cycle.
Diagnosis: If the evaporator is not cold, check to see if the hot gas valve is still open or
if the expansion valve or liquid line valve is not opening properly, if the inlet water valve
is continuing to fill the reservoir, if there are improper unit pressures, or an inoperative
compressor. If the unit remains in 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) – LEDs 1, 4, 3, 2 are on. The 1st pump
out occurs after the 1st freeze cycle. On KM-320MAH-E model, pump out occurs every
10th cycle thereafter. On KM-515MAH-E and KM‑650MAH-E models, pump out occurs
every cycle thereafter. The pump-out cycle (S4 dip switch 5 & 6) can be adjusted to
occur every cycle, or every 2, 5, or 10 cycles.
The compressor remains energized, the hot gas valve energizes, the liquid line valve
and fan motor de‑energize, the pump motor stops for 15 seconds, then starts in reverse
rotation for 10 or 20 seconds. This removes contaminants from the water reservoir.
Diagnosis: If the pump motor does not reverse, check the circuit and pump motor
capacitor. If water does not pump out, check for clear tubing at the check valve housing
and check the unit drain for water flow. Remove the pump-out check 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 turned off. The unit
always restarts at the 1 minute fill cycle.
35
B. Diagnostic Charts
1. No Ice Production
Problem
Possible Cause
[1] The icemaker will not a) Power Supply
start.
Remedy
1. Unplugged.
1. Make sure power switch
is in "OFF" position, then
plug in.
2. Off, blown fuse, or
tripped breaker.
2. Turn on, replace, or reset.
3. Loose connection.
3. Tighten.
4. Bad contacts.
4. Check for continuity and
replace.
5. Not within
specifications.
5. Refer to nameplate and
correct.
b) Transformer (Main
1. Coil winding open or
230V→115V or Control
shorted.
115V→10.5V)
1. Replace.
c) Water Supply
1. Check and get
recommended pressure.
1. Water supply off or
pressure too low.
d) Bin Control Thermostat 1. Tripped with bin filled
with ice.
1. Remove ice.
2. Ambient temperature
too cool.
2. Increase ambient
temperature.
3. Set too warm.
3. See "II.G. Bin Control."
4. Bulb out of position.
4. Place in position.
5. Bad contacts.
5. Check for continuity and
replace.
e) Fuse (Control Box and 1. Blown.
Power Cord Plug)
1. Check for short circuit and
replace.
f) Control Switch
1. "OFF" or "WASH"
position.
1. Move to "ICE" position.
2. Bad contacts.
2. Check for continuity and
replace.
1. Bad contacts.
1. Check for continuity and
replace.
2. Dirty air filter or
condenser.
2. Clean.
3. Ambient temperature
too warm.
3. Reduce temperature.
4. Refrigerant
overcharged.
4. Recover, evacuate, and
recharge.
5. Fan not operating.
5. See chart 1.[7].
g) High Pressure Control
6. Refrigerant line or
6. Clean and replace drier.
components plugged.
h) Wiring to Control Board 1. Loose connections or 1. Check for continuity and
open.
replace.
36
Problem
Possible Cause
[1] The icemaker will not i) Thermistor
start. (continued)
[3] Compressor will
not start or stops
operating.
1. Leads shorted or open 1. See "II.E. Harvest Control
and high temperature
– Thermistor."
or harvest backup
timer safety operates
(1 beep or 2 beep
alarm).
j) 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.
k) Inlet Water Valve
1. Mesh filter or orifice
gets clogged and
water supply cycle
does not finish.
1. Clean.
2. Coil winding open.
2. Replace.
3. Wiring to inlet water
valve.
3. Check for loose
connection or open, and
replace.
1. Bad contacts.
1. Check for continuity and
replace.
2. Float does not move
freely.
2. Clean or replace. See "II.
F. Float Switch."
l) Float Switch
[2] Fill cycle will not
terminate.
Remedy
m)Control Board
1. Defective or in alarm. 1. See "II.D.4. Control Board
Check Procedure."
a) Water Supply
1. Water supply off or
pressure too low.
1. Check and get
recommended pressure.
b) Float Switch
1. Connector
disconnected.
1. Reconnect.
2. Defective switch.
2. Check and replace. See
"II.F. Float Switch."
3. Float does not move
freely.
3. Clean or replace. See "II.
F. Float Switch."
c) Control Board
1. Defective.
1. See "II.D.4. Control Board
Check Procedure."
a) Magnetic Contactor
1. Bad contacts.
1. Check for continuity and
replace.
2. Coil winding open.
2. Replace.
b) Start Capacitor or Run 1. Defective.
Capacitor
1. Replace.
c) Internal Overload
1. Loose terminal.
Protector Open (check 2. Voltage.
1 through 3 to the right
3. Dirty condenser.
and d through f below)
1. Tighten or replace.
d) Starter
1. Bad contacts.
1. Check and replace.
2. Coil winding open.
2. Replace.
37
2. Check and correct.
3. Clean.
Problem
Possible Cause
[3] Compressor will
e) Compressor
not start or stops
operating. (continued)
f) Control Board
[4] Water continues to
a) Water Pressure
be supplied in freeze b) Inlet Water Valve
cycle.
[5] Water pump will not
start.
Remedy
1. Power supply not
within specifications.
1. Refer to nameplate and
correct.
2. Wiring to compressor. 2. Check for loose
connection or open, and
replace.
3. Defective.
3. Replace.
4. Protector tripped.
4. Reduce temperature.
1. No power to contactor. 1. See "II.D.4. Control Board
Check Procedure."
1. Too high.
1. Reduce.
1. Diaphragm does not
close.
1. Check for water leaks with
icemaker off.
c) Control Board
1. Defective.
1. See "II.D.4. Control Board
Check Procedure."
a) Pump Motor
1. Motor winding open.
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] Freeze cycle time is
too short.
[7] Fan motor will
not start, or is not
operating.
b) Control Board
1. Defective.
1. See "II.D.4. Control Board
Check Procedure."
c) Control Switch
1. Bad contacts.
1. Replace.
a) Pump-Out Check Valve 1. Leaking by.
1. Clean or replace.
b) Float Switch
1. Dirty or erratic
operation.
1. Clean or replace. See "II.
F. Float Switch."
c) Control Board
1. Defective.
1. See "II.D.4. Control Board
Check Procedure."
d) Water System
1. Water leaks.
1. Check connections for
water leaks, and replace.
a) Fan Motor
1. Motor winding open.
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.
1. Defective.
1. See "II.D.4. Control Board
Check Procedure."
b) Control Board
38
Problem
Possible Cause
[8] All components
run, but no ice is
produced.
a) Refrigerant
Remedy
1. Low charge.
1. Check for leaks. Recover,
repair, evacuate, and
recharge.
2. Air or moisture
trapped.
2. Recover, replace drier,
evacuate, and recharge.
b) Compressor
1. Defective.
1. Replace.
c) Hot Gas Valve
1. Continues to open in
freeze cycle.
1. Check and replace.
d) Liquid Line Valve
1. Continues to close in
freeze cycle.
1. Check and replace.
e) Inlet Water Valve
1. Wide open during
freeze.
1. Check for water leaks with
icemaker off.
f) Expansion Valve
1. Bulb loose.
1. Secure bulb.
2. Operating erratically.
2. Check and replace.
2. Evaporator is Frozen Up
Problem
Possible Cause
[1]Freeze cycle time is
too long.
a) Inlet Water Valve
Remedy
1. Diaphragm does not
close.
1. Check for water leaks with
icemaker off.
2. Defective switch.
2. Check and replace. See
"II.F. Float Switch."
1. Float does not move
freely.
1. Clean or replace. See "II.
F. Float Switch."
2. Defective switch.
2. Check and replace. See
"II.F. Float Switch."
1. Scaled up.
1. Clean.
2. Damaged.
2. Replace.
1. Dirty.
1. Clean.
2. Out of position.
2. Place in position.
e) Water Pump
1. RPM too slow.
1. See 1.[5].
f) Thermistor
1. Loose or
disconnected.
1. Reattach or connect. See
"II.E. Harvest Control Thermistor."
g) Refrigerant Charge
1. Low charge.
1. Check for leaks. Recover,
repair, evacuate, and
recharge.
h) Expansion Valve
1. Bulb loose.
1. Secure bulb.
2. Operating erratically.
2. Check and replace.
1. Defective.
1. See "II.D.4. Control Board
Check Procedure."
1. Scaled up.
1. Clean.
2. Damaged.
2. Replace.
1. Too cool.
1. Increase temperature.
1. Water pressure too
low.
1. Check and get
recommended pressure.
b) Float Switch
c) Evaporator
d) Spray Tubes
i) Control Board
a) Evaporator
[2]All ice formed on
evaporator does not
fall into bin in harvest
b) Ambient and/or Water
cycle.
Temperature
c) Water Supply Line
39
Problem
Possible Cause
d) Water System
[2]All ice formed on
evaporator does not
fall into bin in harvest
cycle. (continued)
Remedy
1. Water supply line too 1. Increase water line size.
small; requires 13 mm
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
f) Spray Tubes
[3]Other.
1. Dirty mesh filter or
orifice.
1. Clean.
2. Diaphragm does not
close.
2. Check for water leaks with
icemaker off.
1. Dirty.
1. Clean.
2. Out of position.
2. Place in position.
g) Thermistor
1. Out of position or
loose attachment.
1. See "V.G. Removal
and Replacement of
Thermistor."
h) Hot Gas Valve
1. Coil winding open.
1. Replace.
2. Plunger does not
move.
2. Replace.
3. Wiring to hot gas
valve.
3. Check for loose
connection or open, and
replace.
i) Expansion Valve
1. Open.
1. Check and replace.
j) Liquid Line Valve
1. Continues to open in
harvest cycle.
1. Check operation in harvest
cycle and replace.
k) Control Board
1. Harvest timer is set
too short.
1. Adjust longer. See "II.
D.3.b) Harvest Timer (S4
dip switch 1 & 2)."
2. Defective.
2. See "II.D.4. Control Board
Check Procedure."
l) Refrigerant Charge
1. Low Charge
1. Check for leaks. Recover,
repair, evacuate, and
recharge.
a) Ice Cube Guide
1. Out of position.
1. Place in position.
b) Bin Control Thermostat 1. Bulb out of position.
2. Bad contacts.
1. Place in position.
2. Check for continuity and
replace.
3. Low Ice Production
Problem
Possible Cause
[1] Freeze cycle time is
long.
a) Inlet Water Valve
1. Diaphragm does not
close.
1. Check for water leaks with
icemaker off.
b) Float Switch
1. Float switch does not
move freely.
1. Clean or replace. See "II.
F. Float Switch."
2. Defective switch.
2. Check and replace. See
"II.F. Float Switch."
1. Scaled up.
1. Clean.
2. Damaged.
2. Replace.
c) Evaporator
Remedy
40
Problem
Possible Cause
[1] Freeze cycle time is
long. (continued)
d) Spray Tubes
Remedy
1. Dirty.
1. Clean.
2. Out of position.
2. Place in position.
e) Water Pump
1. RPM too slow.
1. Check and replace.
f) Condenser
1. Air filter or condenser 1. Clean.
clogged.
g) Refrigerant Charge
1. Low charge.
1. Check for leaks. Recover,
repair, evacuate, and
recharge.
h) Hot Gas Valve
1. Open.
1. Check and replace.
i) Expansion Valve
1. Bulb loose.
1. Secure bulb.
2. Operating erratically.
2. Check and replace.
j) Compressor
1. Erratic or off.
1. See chart 1. [3].
k) Liquid Line Valve
1. Erratic, sticking.
1. Check and replace.
l) Control Board
1. Float switch
1. Check and reconnect.
connection loose (K5).
2. Defective.
[2] Harvest cycle time is a) Water Supply
long.
2. See "II.D.4. Control Board
Check Procedure."
1. Water temperature too 1. Increase temperature.
cold.
b) Thermistor
1. Out of position or
defective.
1. Reattach and secure.
See "II.E. Harvest Control
– Thermistor."
c) Control Board
1. Not reading
thermistor.
1. Check and replace.
2. Sending voltage to
liquid line valve in
harvest.
2. Check and replace. See
"II.D.4. Control Board
Check Procedure."
d) Inlet Water Valve
1. Clogged.
1. Clean or replace.
e) Evaporator
1. Scaled up.
1. Clean.
f) Hot Gas Valve
1. Does not open, or
opens partially.
1. Check and replace.
g) Expansion Valve
1. Wide open in harvest. 1. Check and replace.
h) Liquid Line Valve
1. Open during harvest
cycle.
1. Check and replace.
4. Abnormal Ice
Problem
Possible Cause
Remedy
[1] Small cubes.
a) Pump-Out Check Valve 1. Dirty or worn and
leaking by.
1. Clean or replace.
b) Ice Cube Guide
1. Out of position.
Circulated water falls
into bin.
1. Place in position.
c) Water System
1. Water supply line too
small.
1. Increase water line size.
See Installation Manual for
proper size.
2. Water filter clogged or 2. Replace filter or install a
flow rate too small.
higher flow rate filter.
41
Problem
Possible Cause
[1] Small cubes.
(continued)
d) Inlet Water Valve
1. Dirty mesh filter or
orifice.
1. Clean.
e) Pump Motor
1. RPM too slow.
1. See chart 1.[5].
f) Control Board
1. Defective.
1. See "II.D.4. Control Board
Check Procedure."
a) Evaporator
1. Frozen up.
1. See chart 2.
2. Scaled up.
2. Clean
3. Damaged.
3. Replace.
1. Water supply line too
small.
1. Increase water line size.
See Installation Manual for
proper size.
[2] Cloudy or irregular
cubes.
b) Water System
Remedy
2. Water filter clogged or 2. Replace filter or install a
flow rate too small.
higher flow rate filter.
c) Spray Guide
3. High hardness or
contains impurities.
3. Install a water softener or
filter.
1. Dirty.
1. Clean.
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. See "II.G. Bin Control."
[2] Abnormal noise.
a) Pump Motor
1. Bearings worn out.
1. Replace.
b) Fan Motor
1. Bearings worn out.
1. Replace.
2. Fan blade deformed.
2. Replace.
3. Fan blade does not
move freely.
3. Replace.
c) Compressor
[3] Ice in storage bin
often melts.
2. Replace.
1. Bearings worn out or 1. Replace.
cylinder valve broken.
2. Mounting pad out of
position.
2. Reinstall.
d) Refrigerant Lines
1. Rub or touch other
lines or surfaces.
1. Reposition.
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.
42
V. Removal and Replacement of Components
IMPORTANT
1. Ensure all components, fasteners, and thumbscrews are securely in place
after the equipment is serviced.
2. The Polyol Ester (POE) oils used in R-404A units can absorb moisture
quickly. Therefore it is important to prevent moisture from entering the
system when replacing or servicing parts.
3. Always install a new drier every time the sealed refrigeration system is
opened. Do not replace the drier until after all other repair or replacement
has been made. Install with the arrow on the drier in the direction of the
refrigerant flow.
4. Do not leave the system open for longer than 15 minutes when replacing or
servicing parts.
A. Service for Refrigerant Lines
WARNING
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. Refrigerant Recovery
The icemaker unit is provided with refrigerant access valves. Using proper refrigerant
practices, recover the refrigerant from the access valves and store it in an approved
container. Do not discharge the refrigerant into the atmosphere.
2. Brazing
WARNING
1. R-404A itself is not flammable at atmospheric pressure and temperatures up
to 176°F (80°C).
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. 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. 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.
43
1) Always install a new drier every time the sealed refrigeration system is opened. Do not
replace the drier until after all other repair or replacement has been made. Install with
the arrow on the drier in the direction of the refrigerant flow.
2) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
Note: Because the pipes in the evaporator case are specially coated to resist corrosion,
it is important to make connections outside the evaporator case when possible. If
it is necessary to braze inside the evaporator case, use sandpaper to remove the
coating from the brazing connections before unbrazing the components.
3) 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.
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 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. Open the service manifold 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.
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.
See the nameplate for the required refrigerant charge. Hoshizaki recommends only
virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition)
be used.
6) A liquid charge is recommended for charging an R-404A system. Invert the service
cylinder and place it on scales. Open the high-side valve on the service manifold.
7) Allow the system to charge with liquid until the proper charge weight is met.
8) If necessary, add any remaining charge to the system through the low-side. Use a
throttling valve or liquid dispensing device to add the remaining liquid charge through
the low-side access port with the unit running.
9) Close the service manifold valves and disconnect the service manifold hoses.
10) Cap the access valves to prevent a possible leak.
44
B. 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. Install with the arrow on the drier in the direction of the refrigerant flow.
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) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Remove the other 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 suction, discharge, and process pipes.
6) Remove the hold-down bolts, washers, and rubber grommets.
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) 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. See the nameplate for the required
refrigerant charge.
15) Connect the terminals and replace the terminal cover in its correct position.
16) Replace all panels except the front panel in their correct positions.
17) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
18) Replace the front panel in its correct position.
45
C. 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. Install with the arrow on the drier
in the direction of the refrigerant flow.
1) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Remove the other 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.
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).
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.
9) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
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 all panels except the front panel in their correct positions.
13) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
14) Replace the front panel in its correct position.
46
D. Removal and Replacement of Hot Gas Valve or Liquid Line Valve
IMPORTANT
1. Always use a copper tube of the same diameter and length when replacing
the hot gas line; otherwise, performance may be affected.
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. Install with the arrow on the drier in the direction of the
refrigerant flow.
3. Always replace the strainer when replacing the hot gas valve.
1) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Remove the other panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the bolt and the solenoid.
5) Disconnect the valve. If replacing the hot gas valve, also remove the strainer.
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.
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) 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 nameplate for the required
refrigerant charge.
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 the bolt.
14) Replace all panels except the front panel in their correct positions.
15) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
16) Replace the front panel in its correct position.
47
E. 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. Install with the arrow on the drier in the direction of the refrigerant flow.
1) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Remove the other panels and the front and top insulation.
3) Recover the refrigerant and store it in an approved container.
4) Remove the spray tubes. Remove the insulation at the "U" shaped notch where the
refrigeration tubing passes through the molded chassis.
5) Disconnect the evaporator tubing.
6) Remove the pop rivets securing the evaporator, then lift out the evaporator.
7) Install the new evaporator.
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. See the nameplate for the required
refrigerant charge.
12) Replace the removed parts in the reverse order of which they were removed.
13) Replace the front and top insulation and all panels except the front panel in their correct
positions.
14) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
15) Replace the front panel in its correct position.
48
F. Removal and Replacement of Condenser
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. Install with the arrow on the drier in the direction of the refrigerant flow.
1) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Remove the other panels.
3) Recover the refrigerant and store it in an approved container.
4) Disconnect the condenser inlet and outlet piping.
5) Remove the side frame, detach the shroud from the condenser, then remove the
condenser assembly.
6) Install the new condenser assembly, then attach the shroud and side frame in their
correct positions.
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 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 nameplate for the required
refrigerant charge.
11) Replace all panels except the front panel in their correct positions.
12) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
13) Replace the front panel in its correct position.
49
G. Removal and Replacement of Thermistor
IMPORTANT
1. 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) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
Thermistor Lead
2) Remove the other 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
Thermistor Holder
Fig. 2
7) Wipe off moisture or condensation on the
suction pipe.
8) Smoothly apply recommended sealant (KE4560RTV, Part Code 60Y000-11 or
4A0683‑01) to the thermistor holder concave.
9) Attach the new thermistor to the suction pipe 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 shorten or cut the thermistor leads.
12) Replace the control box cover and all panels except the front panel in their correct
positions.
13) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
14) Replace the front panel in its correct position.
50
H. 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) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Remove the other panels.
3) Disconnect the fan motor wires.
4) Remove the fan motor bracket and fan motor.
5) Install the new fan motor, connect the fan motor wires, and replace the removed parts
in the reverse order of which they were removed.
6) Replace all panels except the front panel in their correct positions.
7) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
8) Replace the front panel in its correct position.
I. Removal and Replacement of Inlet Water Valve
1) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Close the icemaker water supply line shut-off valve. Open the icemaker water supply
line drain valve.
3) Disconnect the valve outlet tubing by releasing the clamp.
4) Loosen the fitting nut. Be careful not to lose the washer.
5) Disconnect the terminals from the inlet water valve.
6) Remove the bracket and valve from the unit.
7) Install the 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. Connect the wires.
8) Close the icemaker water supply line drain valve. Open the icemaker water supply line
shut-off valve.
9) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
10) Check for leaks.
11) Replace the front panel in its correct position.
51
J. Removal and Replacement of Pump Motor
1) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Remove the base cover.
3) Drain the water tank by removing one end of the pump tubing. See Fig. 3.
4) Disconnect the pump suction and discharge hoses.
5) Remove the closed end connectors from the pump motor leads. Remove the ground
wire.
6) Remove the screw attaching the pump motor assembly to the base, then remove the
pump motor assembly.
7) Remove the screw attaching the pump motor to the pump motor bracket.
8) Remove the screws attaching the pump housing to the pump motor. Remove the
housing and check the impeller.
9) If the impeller is defective, install a new impeller.
10) Install the new motor or new parts. Replace the removed parts in the reverse order of
which they were removed. Connect the wires. Be sure to reattach the green ground
wire.
11) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
12) Check for leaks.
13) Replace the base cover in its correct position.
14) Replace the front panel in its correct position.
Pull Out
Pump Tubing
Do not pull out this side.
Fig. 3
52
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 Sanitizing Instructions
Hoshizaki recommends cleaning this icemaker at least once a year. More frequent
cleaning, however, may be required in some existing water conditions.
WARNING
1. To prevent injury to individuals and damage to the icemaker, do not use
ammonia type cleaners.
2. Always wear liquid-proof gloves to prevent the cleaning and sanitizing
solutions from coming into contact with skin.
3. Carefully follow any instructions provided with the bottles of cleaning and
sanitizing solution.
4. Never run the icemaker when the water tank is empty.
1. Cleaning Procedure
1) Dilute 16 fl. oz. (473 ml) of the recommended cleaner Hoshizaki "Scale Away" or
"LIME‑A-WAY" (Economics Laboratory, Inc.) with 3 gal. (11 l) of warm water.
2) Remove all ice from the evaporator and the storage bin.
Note: To remove cubes on the evaporator, remove the front panel and move the control
switch to the "OFF" position. Wait 3 minutes, then move the control switch back
to the "ICE" position and place the front panel back in its correct position. The
harvest cycle starts and the cubes will be removed from the evaporator.
3) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
4) Remove the base cover, then remove the
insulation panel by lifting up the panel
slightly and pulling it towards you.
Pull Out
5) Remove one end of the pump tubing. See
Fig. 4. Drain the water tank. Replace the
pump tubing in its correct position.
Pump Tubing
Do not pull out this side.
Fig. 4
53
6) In bad or severe water conditions, clean the float switch assembly as described below.
Otherwise, continue to step 7.
a. Disconnect the vent tube and the flush tube from the top of the float switch, then
remove the float switch and rubber boot.
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.
7) Pour the cleaning solution into the water tank.
8) Replace the insulation panel in its correct position.
9) Plug the unit back in, then move the control switch to the "WASH" position to start the
cleaning process.
10) Replace the front panel in its correct position.
11) After 30 minutes, remove the front panel. Move the control switch to the "OFF" position,
then unplug the unit from the mains socket.
12) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in
its correct position.
13) Plug the unit back in, then move the control switch to the "ICE" position to fill the water
tank with water.
14) Replace the front panel in its correct position.
15) After 3 minutes, remove the front panel.
16) Move the control switch to the "WASH" position to rinse off the cleaning solution.
17) Replace the front panel in its correct position.
18) After 5 minutes, remove the front panel.
19) Move the control switch to the "OFF" position, then unplug the unit from the mains
socket.
20) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in
its correct position.
21) Repeat steps 13 through 20 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 warm water. (Add
1.5 fl. oz. (44 ml) of sanitizer to 3 gal. (11 l) of water.)
2) Remove the insulation panel.
3) Pour the sanitizing solution into the water tank.
4) Replace the insulation panel in its correct position.
54
5) Plug the unit back in, then move the control switch to the "WASH" position to start the
sanitizing process.
6) Replace the front panel in its correct position.
7) After 15 minutes, remove the front panel. Move the control switch to the "OFF" position,
then unplug the unit from the mains socket.
8) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in
its correct position.
9) Repeat steps 13 through 20 in "1. Cleaning Procedure" two times to rinse thoroughly.
10) Replace the base cover in its correct position.
11) Clean the storage bin using a neutral cleaner. Rinse thoroughly after cleaning.
12) Plug the unit back in, then move the control switch to the "ICE" position to start the
automatic icemaking process.
13) Replace the front cover in its correct position.
55
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, 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. Air Filters
Plastic mesh air filters remove dirt and 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
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
When shutting off the icemaker for an extended time, drain out all water from
the water tank and remove the ice from the storage bin. The storage bin should
be cleaned and dried. Drain the icemaker to prevent damage to the water
supply line at sub-freezing temperatures, using air or carbon dioxide. Shut off
the icemaker until the proper ambient temperature is resumed.
When the icemaker is not used for two or three days, it is sufficient to 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) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
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 gravity.
4) Attach a compressed air or carbon dioxide supply to the icemaker water supply line
drain valve.
56
5) Make sure at least 3 minutes have elapsed since you unplugged the unit. Plug the unit
back in, then move the control switch to the "ICE" position. Replace the front panel in
its correct position.
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.
2. Drain the water tank:
1) Remove the front panel. Move the control switch to the "OFF" position, then unplug the
unit from the mains socket.
2) Remove the base cover.
3) Remove one end of the pump tubing. Drain the water tank. Replace the pump tubing in
its correct position. See Fig. 5
4) Remove all ice from the storage bin. Clean the storage bin using a neutral cleaner.
Rinse thoroughly after cleaning.
5) Replace the front panel in its correct position.
Pull Out
Pump Tubing
Do not pull out this side.
Fig. 5
57
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