Service Manual

Service Manual
Service Manual
Modular Crescent Cuber with
Models
KML-325MAJ, MWJ
KML-500MAJ, MWJ
KML-700MAJ, MWJ, MRJ
hoshizakiamerica.com
Number: 73215
Issued: 6-16-2017
WARNING
Only qualified service technicians should install and service the appliance. To
obtain the name and phone number of your local Hoshizaki Certified Service
Representative, visit www.hoshizaki.com. No installation or service should be
undertaken until the technician has thoroughly read this Instruction Manual.
Likewise, the owner/manager should not proceed to operate the appliance until the
installer has instructed them on its proper operation. Failure to install, operate, and
maintain the appliance in accordance with this manual will adversely affect safety,
performance, component life, and warranty coverage and may result in costly water
damage. Proper installation is the responsibility of the installer. Product failure or
property damage due to improper installation is not covered under warranty.
Hoshizaki provides this manual primarily to assist qualified service technicians in the
installation, maintenance, and service of the appliance.
Should the reader have any questions or concerns which have not been satisfactorily
addressed, please call, send an e-mail message, or write to the Hoshizaki Technical
Support Department for assistance.
Phone: 1-800-233-1940; (770) 487-2331
Fax: 1-800-843-1056; (770) 487-3360
E-mail: [email protected]
618 Highway 74 South
Peachtree City, GA 30269
Attn: Hoshizaki Technical Support Department
NOTE: To expedite assistance, all correspondence/communication MUST include the
following information:
• Model Number
• Serial Number
• Complete and detailed explanation of the problem.
2
IMPORTANT
This manual should be read carefully before the appliance is serviced. Read
the warnings and guidelines contained in this manual carefully as they provide
essential information for the continued safe use, service, and maintenance of the
appliance. Retain this manual for any further reference that may be necessary.
CONTENTS
Important Safety Information.................................................................................................. 5
I. Construction and Water/Refrigeration Circuit Diagram........................................................ 7
A. Construction................................................................................................................... 7
1. Air-Cooled (MAJ)....................................................................................................... 7
2. Water-Cooled (MWJ)................................................................................................ 8
3. Remote Air-Cooled (MRJ)......................................................................................... 9
B. Water/Refrigeration Circuit Diagram............................................................................. 10
1. Air-Cooled Models (MAJ)........................................................................................ 10
2. Water-Cooled Models (MWJ)...................................................................................11
3. Remote Models (MRJ)............................................................................................ 12
II. Sequence of Operation and Service Diagnosis................................................................ 13
A. Sequence of Operation Flow Chart.............................................................................. 13
1. Operation Flow Chart.............................................................................................. 13
2. Shutdown Flow Chart............................................................................................. 14
B. Service Diagnosis........................................................................................................ 15
C. Control Board Check.................................................................................................... 22
D. Bin Control Check........................................................................................................ 23
E. Switches....................................................................................................................... 24
1. Control Switch......................................................................................................... 24
2. Service Switch........................................................................................................ 24
F. Float Switch Check and Cleaning................................................................................. 25
1. Float Switch Check................................................................................................. 25
2. Float Switch Cleaning............................................................................................. 26
G. Thermistor Check......................................................................................................... 27
H. Diagnostic Tables......................................................................................................... 28
III. Controls and Adjustments................................................................................................ 32
A. Control Board Layout .................................................................................................. 33
B. LED Lights and Audible Alarm Safeties ....................................................................... 34
C. Settings and Adjustments............................................................................................. 35
1. Default Dip Switch Settings..................................................................................... 35
2. Harvest Timer (S4 dip switch 1 & 2)....................................................................... 35
3. Pump-Out Timer (S4 dip switch 3 & 4)................................................................... 36
4. Pump-Out Frequency Control (S4 dip switch 5)...................................................... 36
5. Harvest Pump Time (S4 dip switch 6)..................................................................... 37
6. Harvest Pump Timer Operation (S4 dip switch 7)................................................... 37
7. Factory Use (S4 dip switch 8)................................................................................. 38
8. Freeze Timer (S4 dip switch 9 & 10)....................................................................... 38
9. Float Switch Selector (S5 dip switch 1).................................................................. 38
10. Refill Counter (S5 dip switch 2 and 3)................................................................... 38
11. Minimum Harvest Time (S5 dip switch 4)................................................................ 39
12. Anti-Slush (S5 dip switch 5).................................................................................... 39
3
IV. Refrigeration Circuit and Component Service Information.............................................. 40
A. Refrigeration Circuit Service Information..................................................................... 40
B. Component Service Information................................................................................... 43
C. Water Regulating Valve Adjustment (water-cooled model)........................................... 43
V. Maintenance..................................................................................................................... 44
VI. Preparing the Appliance for Periods of Non-Use............................................................. 45
VII. Disposal.......................................................................................................................... 47
VIII. Technical Information..................................................................................................... 48
A. Specification and Performance Data Sheets................................................................ 48
1. KML-325MAJ........................................................................................................... 48
2. KML-325MWJ......................................................................................................... 49
3. KML-500MAJ.......................................................................................................... 50
4. KML-500MWJ......................................................................................................... 51
5. KML-700MAJ.......................................................................................................... 52
6. KML-700MWJ......................................................................................................... 53
7. KML-700MRJ.......................................................................................................... 54
B. Wiring Diagram ........................................................................................................... 55
4
Important Safety Information
Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, damage to the appliance, or damage to property.
WARNING Indicates a hazardous situation which could result in death or
serious injury.
NOTICE
Indicates a situation which could result in damage to the
appliance or property.
IMPORTANT
Indicates important information about the use and care of the
appliance.
WARNING
The appliance should be destined only to the use for which it has been expressly
conceived. Any other use should be considered improper and therefore dangerous.
The manufacturer cannot be held responsible for injury or damage resulting from
improper, incorrect, and unreasonable use. Failure to service and maintain the
appliance in accordance with this manual will adversely affect safety, performance,
component life, and warranty coverage and may result in costly water damage.
To reduce the risk of death, electric shock, serious injury, or fire, follow basic
precautions including the following:
• Only qualified service technicians should install and service this appliance.
• The appliance must be installed in accordance with applicable national, state, and
local codes and regulations.
• Electrical connection must be hard-wired and must meet national, state, and local
electrical code requirements. Failure to meet these code requirements could result
in death, electric shock, serious injury, fire, or damage.
• The icemaker requires an independent power supply of proper capacity. See the
nameplate for electrical specifications. Failure to use an independent power supply
of proper capacity can result in a tripped breaker, blown fuses, damage to existing
wiring, or component failure. This could lead to heat generation or fire.
• THE ICEMAKER MUST BE GROUNDED. Failure to properly ground the icemaker
could result in death or serious injury.
• Move the control switch to the "OFF" position and turn off the power supply before
servicing. Lockout/Tagout to prevent the power supply from being turned back on
inadvertently.
• To reduce the risk of electric shock, do not touch the control switch or service switch
with damp hands.
• Do not make any alterations to the unit. Alterations could result in electric shock,
injury, fire, or damage to the unit.
• The appliance is not intended for use by persons (including children) with reduced
physical, sensory, or mental capabilities, or lack of experience and knowledge,
unless they have been given supervision or instruction concerning use of the
appliance by a person responsible for their safety.
5
WARNING, continued
• Children should be properly supervised around this appliance.
• Do not climb, stand, or hang on the appliance or allow children or animals to do so.
Serious injury could occur or the appliance could be damaged.
• Do not use combustible spray or place volatile or flammable substances near the
appliance. They might catch fire.
• Keep the area around the appliance clean. Dirt, dust, or insects in the appliance
could cause harm to individuals or damage to the appliance.
Additional Warning for Remote Models
• THE REMOTE CONDENSER UNIT MUST BE GROUNDED. The power supply and
ground connection to the remote condenser unit are supplied from the icemaker.
Failure to properly ground the remote condenser unit could result in death or
serious injury.
• Move the icemaker control switch to the "OFF" position and turn off the power
supply to the icemaker before servicing the remote condenser unit.
Lockout/Tagout to prevent the power supply from being turned back on
inadvertently.
NOTICE
• Follow the instructions in this manual carefully to reduce the risk of costly water
damage.
• In areas where water damage is a concern, install in a contained area with a floor
drain.
• Install the appliance in a location that stays above freezing. Normal operating
ambient temperature must be within 45°F to 100°F (7°C to 38°C).
• Do not leave the icemaker on during extended periods of non-use, extended
absences, or in sub-freezing temperatures. To properly prepare the icemaker for
these occasions, follow the instructions in "VI. Preparing the Appliance for Periods
of Non-Use."
• Do not place objects on top of the appliance.
• The dispenser unit/ice storage bin is for ice use only. Do not store anything else in
the dispenser unit/ice storage bin.
6
I. Construction and Water/Refrigeration Circuit Diagram
A. Construction
1. Air-Cooled (MAJ)
Cleaning Valve
Drain Valve
Thermostatic
Expansion Valve
Water Supply Inlet
Spray Tubes
Inlet Water Valve
Thermostatic
Bin Control
Condenser
Pump Motor
Fan Motor
Control Box
High-Pressure
Switch
Float Switch
Control Switch
Service Switch
Compressor
Thermostatic Bin Control
Bracket & Bulb Holder
Model Shown: KML-500MAJ
7
Liquid Line Valve
Drier
2. Water-Cooled (MWJ)
Thermostatic
Expansion Valve
Spray Tubes
Water Supply Inlet
Water Regulating
Valve
Drain Valve
Cleaning Valve
Inlet Water Valve
Condenser
Thermostatic
Bin Control
High-Pressure
Switch
Control Box
Pump Motor
Float Switch
Drier
Liquid Line Valve
Control Switch
Compressor
Service Switch
Thermostatic Bin Control
Bracket & Bulb Holder
Model Shown: KML-325MWJ
8
3. Remote Air-Cooled (MRJ)
Spray Tubes
Thermostatic
Expansion Valve
Drain Valve
Water Supply Inlet
Hot Gas Valve
Cleaning Valve
Inlet Water Valve
Control Box
High-Pressure
Switch
Control Switch
Service Switch
Reciever
Pump Motor
Float Switch
Drier
Thermostatic
Bin Control
Liquid Line Valve
Compressor
Crankcase Heater
Thermostatic Bin Control
Bracket & Bulb Holder
Model Shown: KML-700MRJ
9
B. Water/Refrigeration Circuit Diagram
1. Air-Cooled Models (MAJ)
Spray Tubes
Condenser
Water Supply Inlet
Inlet Water Valve
Condenser
Fan Motor
Drier
High-Pressure
Switch
Cleaning Valve
Heat Exchanger
Drain Valve
Thermistor
Hot Gas Valve
Water Pump
Float Switch
Compressor
Strainer
Drain
Thermostatic Expansion Valve
10
2. Water-Cooled Models (MWJ)
Water Regulating
Valve
Spray Tubes
Condenser
Water Supply Inlet
Inlet Water Valve
Cleaning Valve
Drier
High-Pressure
Switch
Heat Exchanger
Drain Valve
Thermistor
Hot Gas Valve
Water Pump
Float Switch
Compressor
Strainer
Drain
Thermostatic Expansion Valve
11
3. Remote Models (MRJ)
Condenser
Condenser
Fan Motor
Headmaster
High-Pressure
Switch
Spray Tubes
Water Supply Inlet
Drier
Inlet Water Valve
Receiver
Cleaning Valve
Liquid Line
Valve
Heat Exchanger
Drain Valve
Thermistor
Hot Gas Valve
Water Pump
Float Switch
Compressor
Strainer
Drain
Thermostatic Expansion Valve
12
13
Comp energized
HGV energized
WV energized
FS closed
Thermistor in
control
Thermistor temperature reaches
48°F (9°C) (3.9 kΩ or less). Harvest
timer starts (1 to 3 min.).
FS open
PM energized
WV de-energized
FS check
50 sec.
Harvest Pump
Timer
1 to 3-min. harvest timer in
control (S4 dip switch 1 & 2)
• Maximum inlet water valve time: 6 min. or the length of
harvest minus 50 sec. (S4 dip switch 7), whichever is shorter.
• Maximum harvest time: 20 min.
2. Harvest Cycle
Anti-Slush
Comp continues
Thermistor temperature DV energized
reaches 36°F (2.2°C) HGV energized
(5.8 kΩ).
PM stops for 2 sec., then
PM de-energized for
energized for 10/20 sec.
10 sec.
FM de-energized
FMR de-energized
LLV de-energized
FS in control
FS opens or
freeze timer
terminates
4. Pump-Out Cycle
• Factory set for every
10th cycle
(S4 dip switch 3 & 4)
Power is supplied to the pump motor and drain valve. This drains the water tank.
WASH
Power is supplied to the pump motor and bypass valve. This is used to circulate cleaner and
sanitizer over both the inside and outside surfaces of the evaporator.
CIRCULATE Power is supplied to the pump motor only. This can be used to circulate cleaner over the
outside surface of the evaporator for extended periods of time.
DRAIN
When in the "SERVICE" position, the control switch supplies power to the service switch and the machine is in service mode.
The service switch has three positions: "DRAIN," "CIRCULATE" and "WASH." See the information below for details of each
function.
Comp continues
FM energized
FMR energized
LLV energized
PM energized
HGV de-energized
FS closed
5-min. minimum
freeze timer in
control
3. Freeze Cycle
• Minimum freeze time: 5 min.
• Maximum freeze time: freeze timer
setting (S4 dip switch 9 & 10)
Components Energized when the Control Switch is in the "SERVICE" Position
If FS is open, Comp stops and cycle returns to 1-min. fill.
FS open
WV energized
FS check
1. 1-Minute
Fill Cycle
1. Operation Flow Chart
Legend:
Comp–compressor
DV–drain valve
FM–fan motor
FMR–fan motor-remote
FS–float switch
HGV–hot gas valve
LLV–liquid line valve
PM–pump motor
WV–inlet water valve
Startup
Cycle
Steps
Operation Flow Chart
II. Sequence of Operation and Service Diagnosis
A. Sequence of Operation Flow Chart
14
3. Ice Level Lowered
No ice touching
TBC bulb.
Icemaker starts at
"1. 1-Minute Fill Cycle."
To 1. 1-Minute Fill Cycle
TBC closed
NOTE: control board green "BC CLOSED" LED on
continuously when the K4 jumper is in place.
2. Icemaker Off
All components de-energized.
TBC open
All components
de-energized
Within 10 sec.
after ice contacts
TBC bulb, icemaker shuts down.
1. Bin Full
Ice contacts TBC bulb
TBC Operation
Shutdown
and Restart
Shutdown Flow Chart
2. Shutdown Flow Chart
B. Service Diagnosis
WARNING
• The appliance should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
• Risk of electric shock. Control switch in "OFF" position does not de‑energize all
loads Use extreme caution and exercise safe electrical practices.
• Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.
• Before servicing the appliance, move the control switch to the "OFF" position and
turn off the power supply.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are
securely in place after the appliance is serviced. Make sure that none have fallen
into the dispenser unit/ice storage bin.
• Make sure all food zones in the appliance and dispenser unit/ice storage bin are
clean after service.
The diagnostic procedure is a sequence check that allows you to diagnose the electrical
system and components. Before proceeding, check for correct installation, proper voltage
per nameplate, and adequate water supply. Check CB using the steps in "II.C. Control
Board Check." Check dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, 10
and S5 dip switch 1 through 5 are in the factory default position. S4 dip switch 1, 2, 5, 6
are cleaning adjustments and the settings are flexible. For factory default settings, see
"III.C.1. Default Dip Switch Settings."
Note: • When checking high voltage (115VAC), always choose a white (W) neutral wire to
establish a good neutral connection.
• When checking voltage from the CB K1 connector (10 pin connector), pull
CB K1 connector out slightly to allow room for multimeter test leads contact.
Confirm that the location meets installation requirements:
• The appliance is not intended for outdoor use. Normal operating ambient
temperature should be within 45°F to 100°F (7°C to 38°C).
• Allow 6" (15 cm) clearance at rear, sides, and top for proper air circulation and
ease of maintenance and/or service should they be required.
• The appliance should not be located in a corrosive environment.
1) Turn off the power supply, then access the control box. Move the control switch to the
"OFF" position. Clear any ice from BC.
2) Check that the 115VAC 10A fuse is good.
15
1. Diagnosis
3) Power On: Turn on the power supply, then move the control switch to the "ICE" position.
A 5‑sec. delay occurs. CB red "POWER OK" LED and green "BC CLOSED" LED turn
on. If yellow "BC OPEN" LED is on (indicating a missing or loose jumper (4A4883G01)),
check that the jumper is securely in place. Move ice away from TBC bulb. If yellow "BC
OPEN" LED stays on, see "II.D. Bin Control Check."
Note: • CB red "POWER OK" LED remains on unless the 10.5VAC power supply is
interrupted (K2 connector).
• Check CB using the steps in "II.C. Control Board Check."
• Confirm CB green "BC CLOSED" LED is on. If CB yellow "BC OPEN" LED is on,
confirm jumper (4A5883G01) is in place on CB K4 red connector.
a) Power On Diagnosis: If CB red "POWER OK" LED is off, confirm 10A fuse is good.
Check for 115VAC at control switch #2 (BK) to neutral (W) then at control switch
#3 (P) to neutral (W). If 115VAC is present on #2 (BK) and not on #3 (P), replace
control switch. If 115VAC is present on control switch #3 (P), check for 115VAC at
HPS (P) wire to neutral (W) then HPS (BK) wire to neutral (W). If 115VAC is present
at HPS (P) wire and not at HPS (BK) wire, HPS is open. See HPS Diagnosis below.
If 115VAC is present at HPS (BK) wire, check for 10.5VAC at CB K2 #1 red (R) wire
to CB K2 #2 red (R) wire. If 10.5VAC is not present, check CT continuity. If open,
replace CT.
b) HPS Diagnosis: Let refrigeration circuit pressures equalize. If HPS does not
reset and pressures are equalized, replace HPS. Check that the condenser coil is
not clogged or restricted. If pressures are not equalized, reclaim refrigerant and
diagnose refrigeration circuit restriction. Check that there are no restrictions in the
refrigeration circuit.
Harvest Cycle: HGV, strainer, or check valve.
Freeze Cycle: FM, FMR, TXV, WRV, HM, LLV, strainer, check valve, drier, and
damaged line set or fitting.
4) 1-Min. Fill Cycle – LED 4 is on. WV and X11 relay energize. Water begins to fill the
water tank. After 1 min., CB checks for a closed FS. If FS is closed, the harvest cycle
begins (X10, X12, X14, Comp, HGV, and FMR energize), Continue to step 5a. If FS is
open, WV remains energized through additional 1-min. fill cycles until water enters the
water tank and FS closes (low water safety protection during initial start up and at the
end of each harvest).
Diagnosis: Check that water enters the water tank. If not, check that the water supply
line shut-off valve is open and screens or external filters are clear. Check for 115VAC
at CB K1 #6 (O) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is
present, and WV does not energize, check for 115VAC at WV. If 115VAC is present,
check coil continuity. If open, replace WV. If the water tank fills, but the appliance fails to
start harvest (Comp energized), check for open FS. See "II.E. Float Switch Check and
Cleaning." If FS is closed and CB fails to start the harvest cycle after 1 min., replace
CB.
16
5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp,
HGV, X10, X12, and X14 relays energize. CB monitors the warming of the evaporator
via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C),
CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest
timer (S4 dip switch 1 & 2). The harvest timer has settings of 60, 90, 120, and 180 sec.
The pump‑out timer (S4 dip switch 3 & 4) acts in place of the harvest timer during cycles
with a pump-out (S4 dip switch 5). WV and X11 relay are energized during harvest for a
maximum of 6 min. or the length of harvest minus 50 sec., whichever is shorter. 50 sec.
before harvest terminates, PM energizes. See step 5b below.
a) Comp Diagnosis: Check that evaporator is warming. If not, confirm that Comp
energizes. If not, check for 115VAC at CB K1 #1 or #9 (V) to neutral (W). If 115VAC is
not present, check for 115VAC at CB K1 #7 or #10 (BK) to neutral (W). If 115VAC is
present at #7 or #10 (BK) and not at #1 or #9 (V), replace CB. If 115VAC is present,
check for 115VAC at CR solenoid. If 115VAC is present, confirm contacts are closed.
If not, replace CR. If CR contacts are closed, check Comp start and run capacitors,
Comp start relay, and Comp motor winding.
b) HGV Diagnosis: If Comp is energized and evaporator is not warming, check that HGV
energizes and opens. Check for 115VAC at CB K1 #2 (P) to neutral (W). If 115VAC
is not present, replace CB. If 115VAC is present, check for 115VAC at HGV coil and
check HGV coil continuity. Replace as needed.
c) LLV Diagnosis: Confirm that LLV is de-energized and closed (not bypassing).
If energized, replace CB. If de-energized and bypassing, replace LLV.
d) WRV Diagnosis: Confirm WRV is not leaking by.
e) CCH Diagnosis (remote model): Confirm X14 relay energizes, de-energizing the
CCH.
5b) Harvest Pump Time – LEDs 1, 3, and 2 are on. When the thermistor reaches
48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over
to the harvest timer (S4 dip switch 1 & 2). 50 sec. before the harvest timer terminates,
LED 3 turns on and PM energizes. Comp, HGV, X10, X12, and X14 relays continue.
LED 4 turns off, WV and X11 relay de‑energize.
a) Thermistor Diagnosis: Place a thermometer on the suction line next to the thermistor.
Has it warmed to 48°F (9°C) or warmer? Confirm thermistor status. See "II.F.
Thermistor Check."
b) Control Board Diagnosis: If the thermistor reading is in proper range, dip switch 7 is
on, and WV continues, check for 115VAC at CB K1 #6 (O) to neutral (W). If 115VAC is
present, and LED 4 is off, replace CB. If LED 3 is on and PM is not energized, check
for 115VAC at CB K1 #5 (DBU) to neutral (W). If 115VAC is not present, replace CB.
c) Relay Diagnosis: If 115VAC is present and PM is not energized, check for 115VAC at
X10 relay #8 (Y) to neutral (W). If 115VAC is not present on X10 relay #8 (Y), check
for 115VAC at X10 relay #4 (P) and X10 relay #6 (Y) to neutral (W) (latching circuit). If
115VAC is present at X10 relay #4 (P) and not at X10 relay #6 (Y), replace X10 relay.
If 115VAC is present on X10 relay #8 (Y) and PM is not energized, check for 115VAC
at X10 relay #3 (R) and X10 relay #5 (DBU) to neutral (W). If 115VAC is present at X10
relay #5 (DBU) and not at X10 relay #3 (R), replace X10 relay.
17
d) Control Switch Diagnosis: If 115VAC is present at X10 relay #3 (R), check for
115VAC at control switch #6 red (R) wire to neutral (W). Next, check for 115VAC at
control switch #5 (Y) to neutral (W). If 115VAC is present at control switch #6 red (R)
wire and not at control switch #5 (Y), check control switch continuity. If contacts are
open, replace control switch.
e) Pump Motor Diagnosis: If 115VAC is present at control switch #5 (Y), check PM
capacitor and motor winding continuity.
5c) Initial Harvest Cycle Termination Diagnosis: When the harvest timer (S4 dip switch
1 & 2) terminates, harvest cycle terminates. If 1-min. fill cycle starts after harvest timer
terminates, check that FS is clean and operating properly, see "II.E. Float Switch Check
and Cleaning." If FS is closed, CB proceeds to the next cycle. If not, replace CB.
Note: The minimum total time allowed by CB for a complete harvest cycle is 2 min.
Maximum harvest time allowed is 20 min.
IMPORTANT! S4 dip switch 7 must remain on. Otherwise, PM will not energize
during the last 50 sec. of harvest.
6) Freeze Cycle – LED 1 is on. Comp, PM, and X14 relay continue. FMR, FM, and
LLV energize. HGV, X10, and X12 relays de‑energize. Appliance is held in freeze by a
5-min. short cycle protection timer. After 5-min. timer terminates and FS opens, freeze
cycle terminates. When the thermistor reaches 36°F (2.2°C), CB reads 5.8 kΩ from the
thermistor and de-energizes the PM for 10 sec. (anti-slush). After 10 sec. CB energizes
PM and freeze cycle continues.
Note: PM power supply switches from CB K1 #5 (DBU) in harvest to K1 #4 (R) in freeze.
a) Freeze Cycle Diagnosis: Confirm Comp, PM, and X14 relay continue. Confirm
that FMR, FM, and LLV energize. Confirm WRV opens. Next, confirm HGV, X10,
and X12 relays de-energize. During the first 5 min. of freeze, confirm evaporator is
cooling. If not, confirm WV de-energized (not leaking by), HGV de-energized (not
bypassing), FM, FMR, and LLV energize, TXV and HM operate correctly, WRV
opens, Comp is efficient, and refrigerant charge is correct. See "VIII.A. Specification
and Performance Data Sheets."
When the thermistor reaches 36°F (2.2°C), CB reads 5.8 kΩ from the thermistor and
de‑energizes the PM for 10 sec. then, energizes PM for the duration of the freeze
cycle.
b) Comp Diagnosis: If Comp de-energizes once freeze begins, check that appliance
has not shut off on HPS ("POWER OK" LED off). If so, check "3)b) HPS Diagnosis."
If "POWER OK" LED is on, check for 115VAC at CB K1 #1 (V) or #9 (V) to neutral
(W). If 115VAC is not present and LED 1 is on, replace CB. If 115VAC is present,
check for 115VAC at CR coil. If 115VAC is present, check CR coil and contact
continuity. Replace as needed. If CR is okay, check Comp start relay and start and
run capacitors. Next, check Comp motor winding continuity. If Comp is energized but
evaporator is not cooling, check for an inefficient Comp. See "VIII.A. Specification
and Performance Data Sheets."
18
c) WV and HGV Diagnosis: If WV is energized, check for 115VAC at CB K1 #6 (O) to
neutral (W). If 115VAC is present after PM energizes in harvest cycle, replace CB.
If 115VAC is not present, replace WV (bypassing). If HGV did not de‑energize at
the end of harvest, check for 115VAC at CB K1 #2 (P) to neutral (W). If 115VAC is
present 50 sec. after PM energizes, replace CB. If 115VAC is not present, replace
HGV (bypassing).
d) PM Diagnosis: Confirm water is flowing over evaporator from PM and not WV.
If PM de-energizes once freeze begins or fails to energize after 10 sec. anti-slush,
check for 115VAC at CB K1 #4 (R) to neutral (W). If 115VAC is not present, replace
CB. If 115VAC is present and PM is de-energized, check for 115VAC at control switch
#6 (R) to neutral (W) and control switch #5 (Y) to neutral (W). If 115VAC is present at
control switch #6 (R) and not at control switch #5 (Y), check control switch continuity.
Replace as needed. If 115VAC is present at control switch #5 (Y) to neutral (W),
check PM capacitor and motor winding continuity.
e) FM, FMR, and LLV Diagnosis: If FM, FMR, or LLV does not energize, check for
115VAC at CB K1 #3 (BK) to neutral (W). If 115VAC is not present, replace CB.
If 115VAC is present:
For FM, check capacitor, motor winding, and blade for binding.
For FMR, check for 115VAC at the FMR junction box. If 115VAC is not present, check
icemaker wiring connections. If 115VAC is present, check for voltage at condenser
unit. If 115VAC is not present, check field wiring connections. If 115VAC is present,
check FMR capacitor, motor winding, and fan blade for binding.
For LLV, check coil voltage and continuity.
f) Refrigerant Pressures, HM, and TXV Diagnosis: If evaporator is still not cooling,
check refrigerant pressures. See "VIII.A. Specification and Performance Data
Sheets." Next, check HM operation. If refrigeration pressures are above HM setpoint
and HM is bypassing, replace HM. Check TXV for proper operation. Remove TXV
bulb and hold it in your hand, refrigerant low-side pressure should rise, place
TXV bulb in ice water, refrigerant low-side pressure should drop. A 10 to 15 pound
pressure swing between warm and cold conditions indicate a good TXV. If a 10 to
15 pound swing is not present, replace TXV.
g) WRV Diagnosis: WRV is factory set and generally no adjustment is required.
If WRV fails to open in freeze, check for proper refrigerant pressures. See "VIII.A.
Specification and Performance Data Sheets." If refrigerant pressures are correct and
WRV does not open, adjust or replace as needed. See "IV.C. Water Regulating Valve
Adjustment (water‑cooled models)."
h) Freeze Termination Diagnosis: After 5 min. in freeze, disconnect CB K5 FS
connector. 15 sec. later appliance should switch out of the freeze cycle (15 second
delay after FS opens before terminating the freeze cycle). If appliance remains in
freeze longer than 15 sec. after FS removed, replace CB. If appliance switches with
FS removed but would previously not switch out of freeze with FS connected (long
freeze - 3 beep alarm), see "II.E. Float Switch Check and Cleaning."
Note: Normal freeze cycle will last 20 to 40 min. depending on model and conditions.
Cycle times and pressures should follow performance data provided in this
manual. See "VIII.A. Specification and Performance Data Sheets."
19
i) Short Freeze Cycle Diagnosis: Confirm water tank fills and overflows during 1 min.
fill and harvest cycles. If not, check water supply filters, shut-off valve, WV screen.
If water tank empties before 5 min. timer terminates and freeze cycle is short, check
that DV is not leaking by or energized (water flowing through DV). If DV is leaking by,
remove and clean DV, replace as needed. If water tank is full, see "II.E. Float Switch
Check and Cleaning." for erratic operating FS.
7) Pump-Out Cycle – LEDs 1, 3, and 2 are on (10/20 second pump-out). Timing of the
first pump-out is determined by S4 dip switch 5. See the table below.
Control Board Settings
S4 Dip Switch Setting
No. 5
Pump-Out
Frequency
1st Pump-Out
OFF
Every 10 cycles
After 11th freeze cycle
ON
Every cycle
After 2nd freeze cycle
Comp and X14 relay continue, HGV energizes, FM, FMR, and LLV de-energize.
NOTICE! S4 dip switch 3 & 4 must not be set to 3 off and 4 on. Otherwise, LED
4 turns on energizing WV and X11 relay. Once X10 relay energizes, the DV cannot
energize. PM stops for 2 sec., then PM and DV energize for 10/20 sec. depending on
pump‑out timer (S4 dip switch 3 & 4) setting. When the pump‑out timer terminates,
pump‑out is complete. The pump-out frequency control (S4 dip switch 5) is factory set,
and generally no adjustment is required. However, the pump‑out frequency control
can be set to have a pump-out occur every cycle, or every 10 cycles. For details, see
"III.C.4. Pump‑Out Frequency Control (S4 dip switch 5)."
a) Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after
5 min. of freeze disconnect CB black K5 connector (FS connector). Check that CB
LEDs 1, 3, and 2 are on, PM stops, then re-starts, DV energizes, and water is flowing
down the drain through DV.
b) CB Diagnosis: Confirm FMR, FM, and LLV de-energize. If FRM, FM, or LLV are
energized with LEDs 1, 3, and 2 on, replace CB. If PM does not stop and re-start
and DV does not energize, check that CB LEDs 1, 3, and 2 are on. If not, replace CB.
If LEDs 1, 3, and 2 are on and PM and DV do not energize, check for 115VAC at CB
K1 #5 (DBU) to neutral (W). If 115VAC is not present, replace CB.
c) X10 and X11 Relays: If 115VAC is present at CB K1 #5 (DBU), check for 115VAC
at X10 relay #1 (DBU) to neutral (W). If 115VAC is not present, check that X10 relay
is de‑energized. If X10 relay is de‑energized and 115VAC not present at X10 relay
#1 (DBU), replace X10 relay (contacts sticking). If X10 relay is energized, check
X11 relay status. If X11 relay is energized, check that S4 dip switch 3 and 4 are not
set to 3 on and 4 off positions, if not and X11 is energized, replace CB. If X11 relay is
de‑energized and X10 relay is energized, replace X11 relay (contacts sticking).
d) X12 Relay: If 115VAC is present at X10 #1 (DBU), check for 115VAC at X12 relay
#5 (DBU) to neutral (W) and X12 relay #3 (DBU) to neutral (W). If 115VAC is present
at X12 relay #5 (DBU) and not at X12 relay #3 (DBU), check for 115VAC at X12
relay #8 (P) to neutral (W). If 115VAC is present at X12 relay #8 (P) and X12 relay
is de‑energized, replace X12 relay. If 115VAC is not present, check CB K1 #2 (P) to
neutral (W). If 115VAC is not present (HGV de-energized as well), replace CB.
20
e) X13 Relay - If 115VAC is present at X12 terminal #3 (DBU) to neutral and PM and
DV are not energized, check for 115VAC at X13 terminal #8 (DBU) to neutral (W).
If 115VAC is present and X13 relay is de-energized, replace X13 relay.
(1) For PM and X13 Relay: If 115VAC is present at X13 terminal #8 (DBU), check
for 115VAC at X13 relay #6 (BK) and X13 relay #4 (Y) to neutral (W). If 115VAC
is present at X13 relay #6 (BK) and not at X13 relay #4 (Y), replace X13 relay
(contacts sticking open). If 115VAC is present at X13 relay #4 (Y) and PM is not
energized, check PM capacitor, motor winding, and impeller for binding.
(2) For DV and X13 Relay: If 115VAC is present at X13 terminal #8 (DBU), check for
115VAC at X13 relay #5 (DBU) and X13 relay #3 (W/BU) to neutral (W). If 115VAC
is present at X13 relay #5 (DBU) and not at X13 relay #3 (W/BU), replace X13
relay (contacts sticking open). If 115VAC is present at X13 relay #3 (W/BU) and
DV is de-energized, check DV coil continuity, make sure the drain line is not
clogged and that DV is clean and operating properly.
8) Normal Harvest Cycle – Same as the initial harvest cycle. Return to step 5a) above.
Note: Appliance continues to cycle until TBC is satisfied or power is switched off. The
appliance always restarts at the 1-min. fill cycle.
9) Shutdown
a) Thermostatic Bin Control (TBC):
When the appliance is running, hold ice in contact with the thermostatic bulb. BC
switch opens within 10 sec., shutting down the appliance. TBC is factory set, and
generally no adjustment is required. However, adjustment may be needed in some
conditions, particularly at higher altitude locations.
Diagnosis: See "II.D. Bin Control Check." CB red K4 connector must have the
jumper in place. When the jumper is in place, the green "BC CLOSED" LED remains
on. If the jumper is not in place, yellow "BC OPEN" LED turns on and the icemaker
turns off and remains off until the jumper is replaced in its original position. NOTICE!
CB red K4 connector jumper (4A4883G01) must be in place.
Legend: CB–control board; Comp–compressor; CR–compressor relay;
DV–drain valve; FM–fan motor; FMR–fan motor-remote; FS–float switch;
HGV–hot gas valve; HM–headmaster (C.P.R.); HPS–high-pressure switch;
LLV–liquid line valve; PM–pump motor; TBC; thermostatic bin control;
TXV–thermostatic expansion valve; WRV–water regulating Valve;
WV–inlet water valve
21
C. Control Board Check
Before replacing CB 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.
Alarm Reset: If CB is in alarm (beeping), press the "ALARM RESET" button on CB
while CB is beeping. WARNING! Risk of electric shock. Care should be
taken not to touch live terminals. Once reset, the icemaker starts at the
1-minute fill cycle. For audible alarm information, see "III.B. LED Lights and
Audible Alarm Safeties."
1) Check the dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, 10 and S5 dip
switch 1 through 5 are in the factory default position. S4 dip switch 1, 2, 5, 6 are
cleaning adjustments and the settings are flexible. For factory default settings, see
"III.C.1. Default Dip Switch Settings."
2) Move the control switch to the "ICE" position. If the red "POWER OK" LED is on, control
voltage is good, continue to step 3. If the "POWER OK" LED is off, check CT secondary
circuit. CT output is 10.5VAC at 115VAC primary input. If the secondary circuit has
proper voltage and the red LED is off, replace CB.
If the secondary circuit does not have proper voltage (10.5VAC), check CT primary
circuit. Check for 115VAC at control switch #2 (BK) wire and control switch #3 (P) wire to
neutral (W). If 115VAC is present at control switch #2 (BK) wire and not at control switch
#3 (P) wire, replace control switch. If 115VAC is present at control switch #3 (P) wire,
check for 115VAC at HPS (BK) wire to neutral (W). If 115VAC is not present, see "B.1.
or 2. 3)b) HPS Diagnosis." If 115VAC is present check CT coil continuity. Replace as
needed. For additional checks, see "II.G.1. No Ice Production."
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. For the correct
lighting sequence, see the table below. Note that the order of the LEDs from the outer
edge of the control board is 1, 4, 3, 2. Components (e.g., compressor) cycle during the
test.
Control Board
Correct LED
Lighting Sequence
"J"
1, 4, 3, 2
Following the test, the icemaker begins operation at the 1-minute fill cycle. If the LEDs
do not light as described above, replace CB.
4) To verify voltage output from CB to the components, slide the CB K1 connector out far
enough to allow multimeter lead contact. With the icemaker in the cycle to be tested,
check output voltage from the corresponding pin on CB K1 connector to a neutral (W)
wire. If output voltage is not found and the appropriate LED is on, replace CB.
Legend: CB–control board; CT–control transformer
22
D. Bin Control Check
1. Thermostatic Bin Control Check
TBC shuts down the icemaker within 10 sec. when ice contacts the thermostatic bulb,
regardless of the cycle at activation.
NOTICE
When the ambient temperature is below 45°F (7°C), TBC opens and shuts down
the appliance even if the ice storage bin is empty. When BC is set in the prohibited
range, the appliance operates continuously even if the ice storage bin is filled with
ice. Setting in the prohibited range may result in severe damage to the appliance.
TBC is factory set, and generally no adjustment is required. However, adjustment may be
needed in some conditions, particularly at higher altitude locations.
Note: On thermostatic bin control models, a jumper (4A4883G01) must be placed on
CB red K4 connector. Otherwise, CB yellow "BC OPEN" LED is on and appliance
will not start.
To check TBC, follow the steps below.
1) Turn off the power supply.
2) Remove the front panel, then move the control switch to the "OFF" position.
3) Remove the control box cover, then clear any ice away from TBC bulb.
4) Disconnect TBC wires from TBC switch.
5) Hold your hand around the bulb to warm it up.
6) Check for continuity across TBC switch. If closed, continue to step 6. If open, adjust or
replace TBC.
7) With the multimeter test leads still in place, hold ice on TBC bulb to lower the
temperature. Within 10 sec., TBC switch should open. If it remains closed, adjust or
replace TBC.
Legend: TBC–thermostatic bin control
23
E. Switches
Two control switches are used to control operation. These switches are referred to as the
"control switch" and the "service switch" and are located on the control box.
1. Control Switch
The control switch has three positions: "OFF" for power off, "ICE" for icemaking, and
"SERVICE" to activate the service switch.
2. Service Switch
When the control switch is in the "SERVICE" position, the control switch supplies power
to the service switch and the machine is in service mode. The service switch has three
positions: "DRAIN, "CIRCULATE," and "WASH." See the information below for details of
each function.
Note:
1. When the service switch is activated, power is supplied to the water pump in all
three positions.
2. When the control switch is in the "OFF" position or in the "ICE" position, the
service switch has no power and can be left in any position.
a) DRAIN
This model utilizes a pump-out drain system. When the service switch is active and
placed in the "DRAIN" position, power is supplied to the pump, service relay, and drain
valve.
b) CIRCULATE
When the service switch is active and placed in the "CIRCULATE" position, power is
supplied to the pump only. This operation can be used to circulate cleaner for extended
periods of time over the outside surface of the evaporator.
c) WASH
This model utilizes a solenoid operated wash (bypass) valve. When the service switch is
active and placed in the "WASH" position, power is supplied to the pump and the wash
valve. This operation is used to circulate cleaner and sanitizer over both the inside and
outside of the evaporator.
24
F. Float Switch Check and Cleaning
FS is used to determine that there is sufficient water in the water tank after the 1‑min.
fill cycle and after each harvest cycle. FS 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 FS, follow the steps below.
1) Remove the front panel, then move the control switch to the "SERVICE" position. Move
the service switch to the "DRAIN" position.
2) Allow the water to drain from the water tank, then move the control switch to the "OFF"
position. Turn off the power supply.
3) Remove the control box cover.
4) Disconnect FS connector from CB K5 (black) connector.
5) Check for continuity across FS leads. With the water tank empty, FS should be open.
If open, continue to step 6. If closed, follow the steps in "II.E.2. Float Switch Cleaning."
After cleaning FS, check it again. Replace if necessary.
6) Reconnect FS connector to CB K5 (black) connector, then replace the control box cover
in its correct position.
7) Move the control switch to the "ICE" position. Replace the front panel in its correct
position, then turn on the power supply. After 1 min., the 1-min. fill cycle should end and
the initial harvest cycle should begin. If the initial harvest cycle begins, FS is good and
the check is complete. If the initial harvest cycle does not begin, continue to step 8.
8) Turn off the power supply.
9) Remove the front panel. Move the control switch to the "OFF" position.
10) Remove the control box cover.
11) Disconnect FS connector from CB K5 (black) connector.
12) Check for continuity across FS leads. With the water tank full, FS should be closed.
If FS is closed and the icemaker will not switch from the 1-min. fill cycle to the initial
harvest cycle, replace CB.
If FS is open, confirm that the water tank is full. If the water tank is not full, check the
water supply, water filters, and inlet water valve. If the water tank is full, follow the steps
in "II.E.2. Float Switch Cleaning." After cleaning FS, check it again. Replace if needed.
Legend: CB–control board; FS–float switch
25
2. Float Switch Cleaning
Depending on local water conditions, scale may build up on FS. Scale on the switch can
cause the float to stick. In this case, FS should be cleaned.
1) Remove the front panel, then move the control switch to the "SERVICE" position. Move
the service switch to the "DRAIN" position.
2) Allow the water to drain from the water tank, then move the control switch to the "OFF"
position. Turn off the power supply.
6) Remove the FS from the PM bracket and water tank.
7) Remove the retainer rod from the bottom of FS housing, then remove the float.
Be careful not to bend the retainer rod excessively when removing it. See Fig. 1.
6) Wipe down FS housing, shaft, float, and retainer rod with a mixture of 1 part Hoshizaki
"Scale Away" and 25 parts warm water. Rinse the parts thoroughly with clean water.
7) Reassemble FS assembly and replace it in its correct position.
8) Move the control switch to the "ICE" position.
9) Replace the front panel in its correct position.
10) Turn on the power supply to start the automatic icemaking process.
Legend: CB–control board; FS–float switch; PM–pump motor
Vent
Flush
Shaft
Float Switch
Housing
Float
Fig. 4
Retainer Rod
26
G. Thermistor Check
To check thermistor resistance, follow the steps below.
1) Turn off the power supply.
2) Remove the front panel. Move the control switch to the "OFF" position.
3) Remove the control box cover.
4) Remove the thermistor from the refrigerant tubing.
5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min.
6) Disconnect the thermistor connector from CB K3 connector and check the resistance
between thermistor leads. Normal range is 4.7 to 6.2 kΩ. If outside the normal range,
replace the thermistor. See "IV.B. Component Service Information." If within the normal
range, continue to the next step.
7) Replace the thermistor in its correct position. See "IV.B. Component Service
Information."
8) Reconnect the thermistor connector to CB K3 connector.
9) Replace the control box cover in its correct position.
10) Move the control switch to the "ICE" position.
11) Replace the front panel in its correct position.
12) Turn on the power supply.
13) Once the harvest cycle starts (Comp energizes), begin timing the harvest cycle.
14) The harvest timer and harvest cycle should terminate within 2 to 5 min. If the harvest
cycle does not terminate within 2 to 5 min., replace CB.
Legend: CB–control board; Comp–compressor
27
H. Diagnostic Tables
1. No Ice Production
No Ice Production - Possible Cause
1. Power Supply
a) Off, blown fuse, or tripped breaker.
b) Not within specifications.
2. Thermostatic Bin Control
See "II.D. Bin Control Check"
a) Engaged with bin filled with ice.
b) Ambient temperature too cool.
c) Set too warm.
d) Bulb out of position.
e) Open contacts, defective.
3. Fuse (Control Box)
a) Blown.
4. Control Switch
a) In "OFF" or "SERVICE" position.
b) Bad contacts.
5. High-Pressure Switch
a) Dirty condenser.
b) Fan motor not operating.
c) Refrigerant overcharged.
d) Bad contacts.
e) Refrigerant lines or components plugged.
6. Control Transformer
(115VAC/10.5VAC)
a) Coil winding open or shorted.
7. Control Board
See "II.C. Control Board Check"
a) In alarm.
b) Yellow "BC OPEN" LED on:
Jumper loose or missing on models with TBC.
c) Defective.
8. Water Supply
a) Water supply off or improper water pressure.
b) External water filters clogged.
9. Inlet Water Valve
a) Screen or orifice clogged.
b) Coil winding open.
c) Water valve open in freeze cycle.
10. Float Switch
See "II.E. Float Switch Check
and Cleaning"
a) Float does not move freely.
11. Compressor
a) Compressor relay contacts bad or coil winding open.
b) Defective.
b) Start capacitor or run capacitor defective.
c) Internal protector open.
d) Start relay contacts bad or coil winding open (single phase).
e) Compressor defective.
12. Hot Gas Valve
a) Closed in harvest cycle.
13. Thermistor
See "II.F. Thermistor Check"
a) Loose, disconnected, or defective.
14. Pump Motor
a) Motor winding open.
b) Open in freeze cycle.
b) Bearing worn out or locked rotor.
c) Defective capacitor.
15. Thermostatic Expansion Valve
a) Bulb loose.
b) Operating erratically.
28
No Ice Production - Possible Cause
16. Liquid Line Valve
a) Closed in freeze cycle.
17. Fan Motor/Fan Motor-Remote
(off on HPS)
a) Motor winding open.
b) Open in harvest cycle.
b) Bearing worn out or locked rotor.
c) Defective capacitor.
18. Water System
a) Water leaks causing short freeze time.
2. Freeze-Up
Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up checklist.
See the Hoshizaki America Technician's Pocket Guide or contact your local distributor for a
copy of the freeze-up checklist.
Freeze-Up - Possible Cause
Harvest Cycle
1. Evaporator
a) Scaled up.
b) Damaged.
2. Cube Guides
a) Out of position.
b) Damaged.
3. Spray Tubes and/or Spray
Guides
a) Dirty.
4. Water Supply
a) Low water pressure.
b) Out of position.
b) External water filters clogged.
c) Insufficient water line size.
Minimum 1/4" Nominal ID (6 mm Nominal OD in the EU) copper
water tubing or equivalent.
5. Inlet Water Valve
a) Screen or orifice clogged.
b) Defective.
6. Float Switch
See "II.E. Float Switch Check
and Cleaning"
a) Dirty, sticking.
7. Refrigerant Charge
a) Low.
8. Control Board
See "III.C. Settings and
Adjustments" and "II.C. Control
Board Check"
a) Harvest timer (S4 dip switch 1 & 2) set too short.
b) Defective.
b) Harvest pump timer (S4 dip switch 7) not in factory default position.
c) Defective.
9. Bin Control
See "II.D. Bin Control Check"
a) Thermostatic: Thermostat switch sticking.
10. Thermistor
See "II.F. Thermistor Check"
a) Loose, disconnected, or defective.
11. Thermostatic Expansion Valve
a) Defective.
12. Hot Gas Valve
a) Closed or restricted.
13. Liquid Line Valve
a) Open.
29
Freeze-Up - Possible Cause
Freeze Cycle
1. Evaporator
a) Scaled up.
b) Damaged.
2. Spray Tubes and/or Spray
Guides
a) Dirty.
b) Out of position.
3. Refrigerant Charge
a) Low.
4. Control Board
See "II.C. Control Board Check"
a) Freeze timer (S4 dip switch 9 & 10) set incorrectly.
5. Inlet Water Valve
a) Leaking by.
6. Float Switch
See "II.E. Float Switch Check
and Cleaning"
a) Float does not move freely.
7. Pump Motor
a) RPM too slow.
b) Defective.
b) Defective.
b) Impeller damaged.
8. Thermostatic Expansion Valve
a) Bulb loose or defective.
9. Liquid Line Valve
a) Restricted.
10. Headmaster (C.P.R.)
(remote models)
a) Not bypassing.
3. Low Ice Production
Low Ice Production - Possible Cause
Long Harvest Cycle
1. Evaporator
a) Scaled up.
2. Spray Tubes and/or Spray
Guides
a) Dirty.
3. Refrigerant Charge
a) Low.
4. Water Supply
a) Low water pressure.
b) Out of position.
b) External water filters clogged.
c) Insufficient water line size.
Minimum 1/4" Nominal ID (6 mm Nominal OD in the EU) water
tubing or equivalent.
d) Too cold.
5. Control Board
See "II.C. Control Board Check"
a) Thermistor connection loose (K3).
6. Thermistor
See "II.F. Thermistor Check"
a) Loose, disconnected, or defective.
7. Hot Gas Valve
a) Erratic or closed.
b) Defective.
8. Inlet Water Valve
a) Screen or orifice clogged.
9. Compressor
a) Inefficient or off.
10. Liquid Line Valve
a) Erratic or open.
11. Thermostatic Expansion Valve
a) Defective.
30
Low Ice Production - Possible Cause
Long Freeze Cycle
1. Evaporator
a) Scaled up, dirty.
2. Float Switch
See "II.E. Float Switch Check
and Cleaning"
a) Scaled up, dirty.
b) Float sticking.
c) Defective switch.
3. Inlet Water Valve
a) Leaking by.
4. Hot Gas Valve
a) Erratic or open.
5. Condenser
a) Clogged.
6. Control Board
See "II.C. Control Board Check"
a) Float switch connection loose (K5).
b) Defective.
7. Refrigerant Charge
a) Low.
8. Thermostatic Expansion Valve
a) Bulb loose.
b) Defective.
9. Compressor
10. Pump Motor
a) Inefficient or off.
a) RPM too slow.
11. Liquid Line Valve
a) Erratic or restricted.
12. Headmaster (C.P.R.)
(remote models)
a) Not bypassing.
31
III. Controls and Adjustments
• A Hoshizaki exclusive control board is employed in KML series appliances.
• All models are pretested and factory adjusted.
• For a control board check procedure, see "II.C. Control Board Check."
NOTICE
• Fragile, handle very carefully.
• 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
icemaker when handling or replacing the control board.
• Do not touch the electronic devices on the control board or the back of the control
board.
• Do not change wiring and connections. Do not misconnect K3 WHITE, K4 RED,
and K5 BLACK, because the same connector is used for the thermistor,
mechanical bin control, K4 jumper, and float switch.
• Do not short out power supply to test for voltage.
• Always replace the whole control board assembly if it goes bad.
32
A. Control Board Layout
"J" Control Board
• Bin Control Switch
Closed LED (green)
(on continuously
in thermostatic bin
control application)
• "ALARM RESET" Button
• S4 Dip Switch
• Bin Control Switch
Open LED (yellow)
(mechanical bin control application only)
• K3 (white) Connector
Thermistor
(harvest control and
high temperature safety)
• Alarm Buzzer
• K4 (red) Connector
Mechanical Bin Control or
K4 Jumper (thermostatic
bin control application)
• Ext. Harvest LED
(blue) (lights when
water line thermistor
initiates extended
harvest) Not used
this model
• S5 Dip Switch
• K5 (black) Connector
Float Switch
(water level)
• POWER OK LED
(red) (lights when
10.5VAC is supplied
to K2 connector)
• Part Number
• Relay LEDs
(4) (indicate which
relays are energized
and which K1
connector pins are
energized
• K1 Connector
Pins #1 through #10
#1, 9 Compressor Relay,
X14 Relay
#2 Hot Gas Valve, X12 Relay
#3 Fan Motor,
Fan Motor-Remote
Liquid Line Valve
#4 Pump Motor (icemaking)
#5 Pump Motor
(harvest pump timer and
pump-out)
#6 Inlet Water Valve, X11 Relay
#7, 10 Component Power Supply
#8 Open
• LED 2 (X2 Relay)
LED 2 on:
K1 Connector Pin #2
LED 2 off:
K1 Connector Pin #3
• LED 3 (X3 Relay)
LED 3 on:
K1 Connector Pin #5
LED 3 off:
K1 Connector Pin #4
(energized in freeze)
• LED 4 (X4 Relay)
K1 Connector Pin #6
• LED 1 (X1 Relay)
K1 Connector Pin #1, #9
• "OUTPUT TEST" Button
(used to test relays on control board)
• K2 Connector
Control Transformer (10.5VAC)
"J" Control Board
Part Number 2A7664-01
33
B. LED Lights and Audible Alarm Safeties
At startup, a 5-second delay occurs while the control board conducts an internal timer
check. A beep occurs when the control switch is moved to the "ICE" position. The red
"POWER OK" LED indicates proper control voltage and remains on unless a control
voltage problem occurs. 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 control board is 1, 4, 3, 2.
Sequence Step
LED
1-Minute Fill Cycle
Harvest Cycle
4
1, 4, 2
Harvest Pump Timer
1, 3, 2
Freeze Cycle
1
Pump-Out Cycle
1, 4*, 3, 2
Energized
Components
WV
Comp, HGV,
WV
Comp, HGV,
PM
Comp, FM/
FMR, PM,
LLV
Comp, DV,
HGV, PM, SR,
WV*
Min.
2 minutes
Time LEDs are On
Max.
Avg.
1 minute
20 minutes 3 to 5 minutes
0 seconds 50 seconds harvest pump timer
setting
5 minutes freeze timer 30 to 35 minutes
setting
10 seconds 20 seconds *pump‑out timer
setting
The built-in safeties shut down the icemaker and have alarms as listed below.
No. of Beeps
Type of Alarm
(every 3 sec.)
1
High Evaporator Temp.
(temperature > 127°F) (53°C)
2
Harvest Backup Timer
(harvest > 20 min. for two
cycles in a row)
3
Freeze Timer
(freeze > freeze timer setting
for two cycles in a row)
Notes
Check for harvest problem (stuck HGV or relay), hot
water entering icemaker, or shorted thermistor.
Check for open thermistor, HGV not opening, TXV or
LLV leaking by, low charge, or inefficient Comp, or WRV
leaking by.
Check for FS stuck closed (up), WV leaking by, HGV
leaking by, PM not pumping, TXV not feeding properly,
LLV not opening, low charge, HM not bypassing, or
inefficient Comp.
To reset the above safeties, press the "ALARM RESET" button with the power supply on.
6
Low Voltage
Red LED turns off if voltage protection operates.
(92VAC±5% or less)
The control voltage safeties automatically reset when
voltage is corrected.
7
High Voltage
(147VAC±5% or more)
Legend: Comp–compressor; DV–drain valve; FM–fan motor; FMR–fan motor-remote;
FS–float switch; HGV–hot gas valve; HM–headmaster (C.P.R.); LLV–liquid line
valve; PM–pump motor; SR–service relay; TXV–thermostatic expansion valve;
WRV–water regulating valve; WV–inlet water valve
34
C. Settings and Adjustments
NOTICE
Dip switches are factory set. Failure to maintain factory settings may adversely
affect performance and warranty coverage. For more information, contact your
Hoshizaki Service Center.
1. Default Dip Switch Settings
The dip switches are factory-adjusted to the following positions for the "J" control board:
S4 Dip Switch No.
1
2
3
4
5
6
7
8
9
10
OFF OFF OFF OFF OFF OFF ON OFF OFF OFF
All Models
S5 Dip Switch (Do Not Adjust)
"J" Control Board
1
Dip Switch No.
3
4
5
OFF OFF OFF OFF ON
S5 Dip Switch (Do Not Adjust)
"J" Control Board
Freeze Timer (9 & 10)
Factory Use (8)
Harvest Pump Timer Operation (7) (Do Not Adjust)
ON
1 2 3 4 5 6 7 8 9 10
ON
S4 Dip Switch
"J" Control Board
Harvest Pump Time (6) (Do Not Adjust)
Pump-Out Frequency Control (5)
1 2 3 4 5
All Models
2
Anti-Slush (5)
Minimum
Harvest Time (4)
Refill Counter
(2 and 3)
Float Switch
Selector (1)
Pump-Out Timer (3 & 4)
Harvest Timer (1 & 2)
2. 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 3.9 kΩ from the thermistor. The harvest
timer is factory set, and generally no adjustment is required. However, a setting longer
than the factory setting may be advised in cases where the drain provided at harvest
needs to be prolonged for extra cleaning. Before changing this setting, contact Hoshizaki
Technical Support at 1‑800‑233-1940 for recommendations. Keep in mind that setting the
harvest timer to a longer setting decreases 24-hour production.
Note that the pump-out timer (S4 dip switch 3 & 4) acts in place of the harvest timer
during cycles with a pump out. For details, see "III.C.3. Pump-Out Timer (S4 dip switch
3 & 4)."
Note: On models with a pump-out every cycle, 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
(sec.)
OFF
OFF
60
ON
OFF
90
OFF
ON
120
ON
ON
180
35
3. Pump-Out Timer (S4 dip switch 3 & 4)
NOTICE
Do not adjust 3 off and 4 on. Drain valve does not energize in this setting.
When a pump-out is called for, the pump motor stops for 2 sec. After 2 sec. the drain
valve and pump motor energize. Water is removed from the bottom of the water tank
and sent down the drain. The pump‑out drains the water tank for the time determined by
the pump‑out timer. The pump‑out timer also acts in place of the harvest timer during
cycles with a pump-out. The pump-out timer is factory set, and generally no adjustment
is required. However, where water quality is bad and the icemaker needs a longer
pump‑out time, the pump-out timer can be adjusted. The pump-out timer control can be
set to pump-out for 10 or 20 seconds.
S4 Dip Switch Setting
Time (sec.)
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
4. Pump-Out Frequency Control (S4 dip switch 5)
The pump-out frequency control is factory set to drain the water tank every 10 cycles.
Generally no adjustment is required. However, where water quality is bad and the
icemaker needs a pump-out more often, the pump‑out frequency can be adjusted. The
pump-out frequency control can be set to have a pump‑out occur every cycle, or every
10 cycles.
The first pump-out is dependent on S4 dip switch 5. See the table below.
S4 Dip Switch Setting
Pump-Out Frequency
1st Pump-Out
OFF
Every 10 cycles
After 11th freeze cycle
ON
Every cycle
After 2nd freeze cycle
No. 5
36
5. Harvest Pump Time (S4 dip switch 6)
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside of the factory
default setting may result in damage to the appliance.
The harvest pump time starts with 50 sec. left to go in the harvest time (S4 dip switches
1 & 2) after the thermistor reaches 48°F (9°C) at the evaporator outlet and the control
board reads 3.9 kΩ from the thermistor. The harvest pump time is factory set, and no
adjustment is required.
S5 Dip Switch Setting Harvest Pump Time
No. 6
OFF
50 sec.
ON
25 sec.
6. Harvest Pump Timer Operation (S4 dip switch 7)
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside of the factory
default setting may result in damage to the appliance.
Depending on the harvest pump time operation setting, the pump motor either stays
off or is energized the last 50 seconds of harvest. When the pump motor is energized,
water circulates over the evaporator. The harvest water valve is open during harvest for
a maximum of 6 minutes or the length of harvest minus 0 or 50 seconds (determined by
the harvest pump timer setting), whichever is shorter.
When S4 dip switch 7 is in the on position and harvest begins, X10, X11 and X12
relays energize. A latching circuit is created through the X11 and X10 relays. For further
details, see "VIII.B. Wiring Diagram." 50 sec. before harvest termination, LED 4 turns off,
inlet water valve and X11 relay de‑energize. X10 relay remains energized through the
latching circuit. Next, LED 3 turns on and control board K1 connector pin #5 (DBU) wire
energizes, energizing the pump motor for the last 50 sec. of harvest.
S4 Dip Switch Setting
No. 7
Pump Motor
Time (sec.)
OFF
Disabled
ON
Enabled
37
7. Factory Use (S4 dip switch 8)
Factory set for proper operation. Do not adjust. This must be left in the factory default
position.
8. Freeze Timer (S4 dip switch 9 & 10)
NOTICE
Adjust to proper specification, or the icemaker 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 or pump-out cycle. After 2 consecutive freeze timer terminations, the
control board shuts down the icemaker. In this case, see "II.G.3. Low Ice Production"
for possible solutions. The freeze timer is factory set and no adjustment is required.
Before changing this setting, contact Hoshizaki Technical Support at 1‑800‑233-1940 for
recommendations.
S4 Dip Switch Setting
No. 9
No. 10
Time
(min.)
OFF
OFF
60
ON
OFF
70
OFF
ON
50
ON
ON
85
9. Float Switch Selector (S5 dip switch 1)
This dip switch setting allows use of this control board in single and dual float switch
models. This model uses a single float switch style.
NOTICE
Do not adjust. This must be left in the factory default position or the icemaker will
not operate correctly.
S5 Dip Switch Setting
No. 1
Top or Bottom Float Switch
Control
OFF
Bottom Float Switch Enabled
ON
Top Float Switch Enabled
10. Refill Counter (S5 dip switch 2 and 3)
NOTICE
Do not adjust. These must be left in the factory default position or the icemaker will
not operate correctly. This model does not utilize refill.
S5 Dip Switch Setting
No. 2
No. 3
Refill
Counter
OFF
OFF
0
ON
OFF
9 refills
OFF
ON
1 refill
ON
ON
10 refills
38
11. Minimum Harvest Time (S5 dip switch 4)
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside the factory
default setting may result in damage to the appliance.
S5 Dip Switch Setting
No. 4
Minimum
Harvest Timer
OFF
120 sec.
ON
70 sec.
12. Anti-Slush (S5 dip switch 5)
This dip switch setting provides anti-slush control during the freeze cycle. When the
evaporator temperature reaches 36°F (2.2°C) the control board reads a 5.8kΩ signal
from the thermistor and de-energizes the water pump for 10 sec. to melt the ice slush
and prevent the ice slush from blocking the water supply tubing, causing irregular freeze
patterns.
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside the factory
default setting may result in damage to the appliance.
S5 Dip Switch Setting
No. 9
Anti-Slush
OFF
Disabled
ON
Enabled
39
IV. Refrigeration Circuit and Component Service Information
WARNING
• This appliance should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
• Move the control switch to the "OFF" position and turn off the power supply. Place
the disconnect in the "OFF" position. Lockout/Tagout to prevent the power supply
from being turned back on inadvertently.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are
securely in place after the icemaker is serviced. Make sure that none have fallen
into the dispenser unit/ice storage bin.
• Make sure all food zones in the icemaker and dispenser unit/ice storage bin are
clean after service.
A. Refrigeration Circuit Service Information
WARNING
• Repairs requiring the refrigeration circuit to be opened must be performed by
properly trained and EPA-certified service personnel.
• 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.
NOTICE
• Always recover the refrigerant and store it in an approved container. Do not
discharge the refrigerant into the atmosphere.
• Do not leave the system open for longer than 15 min. when replacing or servicing
parts. The Polyol Ester (POE) oils used in R-404A applications can absorb
moisture quickly. Therefore it is important to prevent moisture from entering the
system when replacing or servicing parts.
• Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repair or replacement has been made.
Install the new drier with the arrow on the drier in the direction of the refrigerant
flow.
• When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
1. Refrigerant Recovery
The icemaker is provided with refrigerant access valves. Using proper refrigerant practices,
recover the refrigerant. Store the refrigerant in an approved container. Do not discharge the
refrigerant into the atmosphere.
40
2. Brazing
WARNING
• R-404A itself is not flammable at atmospheric pressure and temperatures up to
176°F (80°C).
• 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.
• Do not use silver alloy or copper alloy containing arsenic.
1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
Note: Because the pipes in the evaporator case are specially coated to resist corrosion,
it is important to make connections outside the evaporator case when possible. If
it is necessary to braze inside the evaporator case, use sandpaper to remove the
coating from the brazing connections before unbrazing the components.
NOTICE
• Always install a new drier every time the sealed refrigeration system is opened.
• Do not replace the drier until after all other repair or replacement has been made.
Install the new drier with the arrow on the drier in the direction of the refrigerant
flow.
• When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
2) Use an electronic leak detector or soap bubbles to check for leaks. Add 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 refrigerant 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 gauge 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 gauge manifold.
41
5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a
refrigerant service cylinder. Remember to loosen the connection and purge the air from
the hose. For the required refrigerant charge, see the rating label inside the icemaker.
Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets
AHRI Standard 700 (latest edition) be used.
6) A liquid charge is required when charging an R-404A system (to prevent fractionation).
Place the service cylinder on the scales; if the service cylinder is not equipped with
a dip tube, invert the service cylinder, then place it on the scales. Open the high-side
valve on the gauge manifold.
7) Allow the system to charge with liquid until the proper charge weight is met.
8) If necessary, add any remaining charge to the system through the low-side.
NOTICE! To prevent compressor damage, use a throttling valve or liquid
dispensing device to add the remaining liquid charge through the low-side
refrigerant access valve with the icemaker running.
9) Close the high and low-side gauge manifold valves, then disconnect the gauge manifold
hoses.
10) Cap the refrigerant access valves to prevent a possible leak.
42
B. Component Service Information
NOTICE
When replacing a component listed below, see the notes to help ensure proper
operation.
Component
Compressor
Notes
1 phase: Install a new start capacitor, run capacitor, and start relay.
3 phase: Install a new magnetic contactor.
Thermostatic
• Attach the thermostatic expansion valve bulb to the suction line in the same location as
Expansion Valves the previous bulb.
• The bulb should be between the 10 and 2 o'clock positions on the tube.
• Secure the bulb with the clamp and holder, then insulate it.
Hot Gas Valves
Liquid Line
Valves
• Replace the strainer if applicable.
Fan Motors
Install a new capacitor.
Pump Motor
Install a new capacitor.
Thermistor
• Attach the new thermistor to the suction line in the same location as the previous
thermistor.
• Use copper tube of the same diameter and length when replacing valve lines.
• The thermistor should be at the 12 o'clock position on the tube.
• Smoothly fill the recessed area of the thermistor holder with high thermal conductive
type sealant. Hoshizaki America part number 4A0683-01 (Silicone Heat Sink Compound
10-8108 manufactured by GC Electronics), KE-4560 RTV (manufactured by ShinEtsu
Silicones), or equivalent are recommended.
• Secure the thermistor with the holder, then insulate it.
• Be very careful to prevent damage to the leads.
C. Water Regulating Valve Adjustment (water-cooled model)
The water regulating valve is factory set, and generally no adjustment is required. However,
when necessary, adjust the water regulator using the following procedure.
1) Prepare a thermometer to check the condenser drain temperature. Attach a pressure
gauge to the high-side line of the system.
2) 5 min. after a freeze cycle starts, confirm
that the thermometer reads 104°F to 115°F
(40°C to 46°C). If it does not, rotate the
adjustment screw by using a flat blade
screwdriver until the temperature is in the
proper range. See Fig. 4. Next, check that
the reference pressure is in the range
indicated in the Head Pressure table in the
Performance Data section. If it is not in the
proper range, verify the refrigerant charge.
Adjustment Screw
CW – Higher
CCW – Lower
Top View
3) Check that the condenser drain temperature is stable.
43
Fig. 4
V. Maintenance
The maintenance schedule below is a guideline. More frequent maintenance may be
required depending on water quality, the appliance's environment, and local sanitation
regulations
WARNING
• Only qualified service technicians should service the appliance.
• To reduce the risk of electric shock, do not touch the control switch or service
switch with damp hands
• Before servicing: Move the control switch to the "OFF" position and turn off the
power supply. Place the disconnect in the "OFF" position.
Lockout/Tagout to prevent the power supply from being turned back on
inadvertently.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are
securely in place after any maintenance is done to the icemaker. Make sure that
none have fallen into the dispenser unit/ice storage bin.
Maintenance Schedule
Frequency Area
Task
Daily
Scoop
Bi-Weekly
Monthly
Clean the ice scoop using a neutral cleaner. Rinse thoroughly after
cleaning.
Inspect. Wash with warm water and neutral cleaner if dirty.
Check for proper pressure and change if necessary.
Air Filters
External Water
Filters
Icemaker Exterior Wipe down with a clean, soft cloth. Use a damp cloth containing a
neutral cleaner to wipe off oil or dirt build up. Clean any chlorine staining
(rust colored spots) using a non-abrasive cleanser.
Wipe down with a clean cloth and warm water.
Underside of
Icemaker and Top
Kits; Bin Door and
Snout
Icemaker and
Clean and sanitize per the cleaning and sanitizing instructions provided
Dispenser Unit/Ice in the instruction manual or maintenance label on the icemaker.
Storage Bin Liner
Water Supply Inlet Close the icemaker water supply line shut‑off valve and drain the water
system. Clean the water supply inlet screen.
Condenser
Inspect. Clean if necessary by using a brush or vacuum cleaner. More
frequent cleaning may be required depending on location.
Water Hoses
Inspect the water hoses and clean/replace if necessary.
Yearly
44
VI. Preparing the Appliance for Periods of Non-Use
NOTICE
• When storing the appliance for an extended time or in sub-freezing temperatures,
follow the instructions below to prevent damage.
• The pump motor is energized continuously when the control switch is in the
"SERVICE" position.
When the appliance is not used for two or three days under normal conditions, it is
sufficient to move the control switch to the "OFF" position. When storing the appliance for
an extended time or in sub-freezing temperatures, follow the instructions below.
1. Remove the water from the icemaker water line:
1) Turn off the power supply, then remove the front panel.
2) Move the control switch on the control box to the "OFF" position.
3) Close the icemaker water supply line shut-off valve, then open the icemaker water
supply line drain valve.
4) Allow the line to drain by gravity.
5) Attach compressed air or carbon dioxide supply to the icemaker water supply line drain
valve.
6) Make sure at least 3 min. have elapsed since you turned off the power supply. Move
sure the control switch is in the "ICE" position.
7) Replace the front panel in its correct position, then turn on the power supply.
8) Blow the icemaker water supply line out using compressed air or carbon dioxide.
2. Drain the water tank:
1) Turn off the power supply, then remove the front panel.
2) Move the service switch to the "DRAIN" position, then move the control switch to the
"SERVICE" position.
3) Replace the front panel in its correct position, then turn on the power supply for
2 minutes.
4) After 2 min., turn off the power supply, then remove the front panel.
5) Move the control switch to the "OFF" position.
6) Replace the front panel in its correct position.
7) Remove all ice from the dispenser unit/storage bin. Clean the dispenser unit/storage bin
using a neutral cleaner. Rinse thoroughly after cleaning.
8) Close the icemaker water supply line drain valve.
45
3. On water-cooled model, remove the water from the water-cooled condenser:
1) Make sure the power supply is off, then remove the front panel and right side panel.
2) Close the condenser water supply line shut-off valve. If connected to a closed loop
system, also close the condenser return line shut-off valve.
3) Open the condenser water supply line drain valve. If connected to a closed loop system,
also open the condenser return line drain valve.
4) Attach a compressed air or carbon dioxide supply to the condenser water supply line
drain valve.
5) Open the water regulating valve by using a screwdriver to pry up on the spring retainer
underneath the spring. While holding the valve open, blow out the condenser using the
compressed air or carbon dioxide supply until water stops coming out.
6) Close the drain valve(s).
7) Replace the right side panel and front panel in their correct positions.
46
VII. Disposal
The appliance contains refrigerant and must be disposed of in accordance with
applicable national, state, and local codes and regulations. Refrigerant must be
recovered by properly certified service personnel.
47
VIII. Technical Information
We reserve the right to make changes in specifications and design without prior notice.
A. Specification and Performance Data Sheets
Pressure data is recorded at 5 min. into freezing cycle. The data not in bold should be
used for reference only.
1. KML-325MAJ
Specification Sheet
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
115/60/1
8.4 A (5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
90/70°F
70/50°F
720 (5.72)
710 (4.51)
60 (19.9)
161 (42.3)
8.1 lbs. (3.7 kg) 360pcs.
Thermostat
R404A, 1 lb. 5.2 oz. (600g)
Performance Data Sheet
APPROXIMATE ICE PRODUCTION PER AMBIENT TEMP.
(ºF/ºC)
24 HR.
70/21
80/27
70/21
APPROXIMATE ELECTRIC
80/27
CONSUMPTION
90/32
watts
100/38
70/21
APPROXIMATE WATER
80/27
CONSUMPTION PER 24 HR.
90/32
3
gal./day m /day
100/38
70/21
FREEZING CYCLE TIME
80/27
90/32
min.
100/38
70/21
HARVEST CYCLE TIME
80/27
90/32
min.
100/38
70/21
HEAD PRESSURE
80/27
90/32
PSIG kg/cm2G
100/38
70/21
SUCTION PRESSURE
80/27
90/32
PSIG kg/cm2G
100/38
380
362
50/10
161
138
131
97
213
225
229
242
55
56
56
56
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
710
712
713
716
26
28
29
29
4.0
3.6
3.4
2.8
172
164
0.61
0.52
0.50
0.37
15.0
15.8
16.1
17.0
3.9
3.9
3.9
4.0
WATER TEMP. (ºF/ºC)
70/21
357
162
326
148
713
717
720
722
131
0.50
92
0.35
60
0.23
57
0.22
29
31
33
34
3.4
2.7
2.1
2.1
229
16.1
250
17.6
267
18.8
277
19.5
56
3.9
57
4.0
58
4.1
58
4.1
331
304
114
88
50
41
266
296
310
350
58
59
60
62
90/32
722
728
730
740
32
35
37
40
3.2
2.8
2.1
2.1
150
138
0.43
0.33
0.19
0.15
18.7
20.8
21.8
24.6
4.1
4.2
4.2
4.4
5,800 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
900 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
48
2. KML-325MWJ
Specification Sheet
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
WATER COOLED CONDENSER
gal./24HR (gal./100 lbs.)
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
Performance Data Sheet
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
115/60/1
8.4 A (5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
90/70°F
70/50°F
670 (4.51)
690 (4.31)
60 (17.0)
122 (31.6)
376 (106)
155 (40)
7.9 lbs. (3.6 kg) 360pcs.
Thermostat
R404A, 1 lb. 1.6 oz. (500g)
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
80/27
90/32
100/38
70/21
80/27
90/32
100/38
70/21
80/27
90/32
100/38
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
WATER FLOW FOR CONDENSER
PRESSURE DROP OF COOLING WATER LINE
385
378
376
372
277
313
324
402
267
267
268
270
56
56
56
56
50/10
690
686
684
682
26
27
27
26
3.3
3.0
2.9
2.5
175
172
171
169
1.05
1.18
1.23
1.52
18.8
18.8
18.8
19.0
3.9
3.9
3.9
4.0
WATER TEMP. (ºF/ºC)
70/21
376
171
365
165
355
161
351
159
684
676
670
668
324
1.23
385
1.46
437
1.65
458
1.73
27
28
29
28
2.9
2.5
2.1
2.1
268
18.8
268
18.9
269
18.9
270
19.0
56
3.9
55
3.9
55
3.9
55
3.9
362
349
339
325
406
478
527
610
272
275
275
281
56
57
56
57
90/32
674
666
660
650
25
25
26
24
2.8
2.5
2.1
2.0
164
158
154
147
1.54
1.81
1.99
2.31
19.2
19.4
19.4
19.8
4.0
4.0
3.9
4.0
5,500 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
900 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
23 gal./h [AT 100ºF (38ºC) / WT 90ºF (32ºC)]
less than 10 PSIG
ENG.F-011.1.0205
49
3. KML-500MAJ
Specification Sheet
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
gal./day m3/day
FREEZING CYCLE TIME
min.
HARVEST CYCLE TIME
min.
HEAD PRESSURE
2
PSIG kg/cm G
SUCTION PRESSURE
PSIG
kg/cm2G
115/60/1
7.6 A ( 5 Min. Freeze AT 104°F / WT 80°F)
20 A
20 A
90/70°F
70/50°F
930 (5.55)
850 (4.64)
64 (16.0)
143 (32.4)
7.9 lbs. (3.6 kg) 360pcs.
Thermostat
R404A, 1 lb. 10.5 oz. (750g)
AMBIENT TEMP.
(ºF/ºC)
70/21
80/27
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
80/27
90/32
100/38
70/21
80/27
90/32
100/38
442
433
143
126
120
93
250
264
268
271
57
57
58
58
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
50/10
850
868
873
867
23
23
24
24
3.5
3.2
3.1
2.6
200
196
0.54
0.48
0.45
0.35
17.6
18.6
18.9
19.0
4.0
4.0
4.0
4.1
WATER TEMP. (ºF/ºC)
70/21
430
195
413
188
873
904
930
930
120
0.45
89
0.34
64
0.24
62
0.24
24
25
26
27
3.1
2.5
2.0
2.0
268
18.9
293
20.6
313
22.0
318
22.3
58
4.0
58
4.1
59
4.1
59
4.2
399
376
107
87
57
50
289
310
332
350
59
60
61
62
90/32
881
898
930
930
25
27
28
30
2.9
2.6
2.0
2.1
181
170
0.40
0.33
0.21
0.19
20.3
21.8
23.4
24.6
4.1
4.2
4.3
4.4
6,200 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,200 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
ENG.F-011.1.0205
50
4. KML-500MWJ
Specification Sheet
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
WATER COOLED CONDENSER
gal./24HR (gal./100 lbs.)
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
3
gal./day m /day
FREEZING CYCLE TIME
min.
HARVEST CYCLE TIME
min.
HEAD PRESSURE
2
PSIG kg/cm G
SUCTION PRESSURE
PSIG
kg/cm2G
115/60/1
9.6 A (5 Min. Freeze AT 104°F / WT 80°F)
20 A
20 A
90/70°F
70/50°F
930 (4.33)
890 (3.93)
82 (16.0)
125 (22.9)
567 (110)
279 (51)
7.9 lbs. (3.6 kg) 360pcs.
Thermostat
R404A, 0 lb. 15.9 oz. (450g)
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
80/27
90/32
100/38
70/21
80/27
90/32
100/38
70/21
80/27
90/32
100/38
543
537
535
528
403
458
475
588
275
276
276
276
57
57
57
57
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
WATER FLOW FOR CONDENSER
PRESSURE DROP OF COOLING WATER LINE
50/10
890
899
902
900
18
19
19
19
2.6
2.5
2.5
2.3
246
243
243
239
1.53
1.73
1.80
2.23
19.3
19.4
19.4
19.4
4.0
4.0
4.0
4.0
WATER TEMP. (ºF/ºC)
70/21
535
243
524
238
515
234
510
231
902
917
930
931
475
1.80
570
2.16
649
2.46
676
2.56
19
20
20
21
2.5
2.2
2.1
2.0
276
19.4
278
19.6
280
19.7
280
19.7
57
4.0
57
4.0
57
4.0
57
4.0
515
499
492
470
584
684
763
868
277
279
281
281
57
57
57
57
90/32
909
920
935
940
20
21
21
23
2.4
2.3
2.0
2.0
233
226
223
213
2.21
2.59
2.89
3.29
19.5
19.6
19.7
19.8
4.0
4.0
4.0
4.0
8,000 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
33 gal./h [AT 100ºF (38ºC) / WT 90ºF (32ºC)]
less than 10 PSIG
ENG.F-011.1.0205
51
5. KML-700MAJ
Specification Sheet
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
gal./day m3/day
FREEZING CYCLE TIME
min.
HARVEST CYCLE TIME
min.
HEAD PRESSURE
2
PSIG kg/cm G
SUCTION PRESSURE
PSIG
kg/cm2G
115/60/1
14.2 A (5 Min. Freeze AT 104°F / WT 80°F)
20 A
20 A
90/70°F
70/50°F
1230 (5.16)
1120 (4.10)
92 (16.0)
223 (33.9)
10.4 lbs. (4.7 kg) 480pcs.
Thermostat
R404A, 2 lb. 10.3 oz. (1200g)
AMBIENT TEMP.
(ºF/ºC)
70/21
80/27
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
80/27
90/32
100/38
70/21
80/27
90/32
100/38
658
639
223
194
185
141
258
271
275
282
54
56
56
55
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
50/10
1120
1145
1152
1164
20
21
21
22
3.6
3.2
3.1
2.7
298
290
0.84
0.73
0.70
0.53
18.1
19.1
19.3
19.8
3.8
3.9
3.9
3.9
WATER TEMP. (ºF/ºC)
70/21
633
287
600
272
1152
1195
1230
1242
185
0.70
134
0.51
92
0.35
90
0.34
21
23
25
25
3.1
2.5
2.1
2.1
275
19.3
297
20.9
316
22.2
323
22.7
56
3.9
59
4.1
61
4.3
61
4.3
588
549
166
134
84
76
303
328
346
374
57
58
61
61
90/32
1202
1247
1282
1330
24
26
27
29
3.0
2.7
2.1
2.1
267
249
0.63
0.51
0.32
0.29
21.3
23.1
24.3
26.3
4.0
4.1
4.3
4.3
11,300 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,500 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
52
ENG.F-011.1.0205
6. KML-700MWJ
Specification Sheet
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
WATER COOLED CONDENSER
gal./24HR (gal./100 lbs.)
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
3
gal./day m /day
FREEZING CYCLE TIME
min.
HARVEST CYCLE TIME
min.
HEAD PRESSURE
2
PSIG kg/cm G
SUCTION PRESSURE
PSIG
kg/cm2G
115/60/1
12.6 A (5 Min. Freeze AT 104°F / WT 80°F)
20 A
20 A
90/70°F
70/50°F
1100 (3.61)
1070 (3.40)
117 (16.0)
181 (24.0)
810 (111)
454 (60)
10.7 lbs. (4.8 kg) 480pcs.
Thermostat
R404A, 1 lb. 6 oz. (625g)
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
80/27
90/32
100/38
70/21
80/27
90/32
100/38
70/21
80/27
90/32
100/38
756
750
748
720
635
700
721
1062
237
238
238
239
58
58
59
59
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
WATER FLOW FOR CONDENSER
PRESSURE DROP OF COOLING WATER LINE
50/10
1070
1077
1079
1080
18
18
18
18
2.9
2.7
2.7
2.4
343
340
339
326
2.40
2.65
2.73
4.02
16.7
16.7
16.7
16.8
4.1
4.1
4.1
4.1
WATER TEMP. (ºF/ºC)
70/21
748
339
738
335
730
331
712
323
1079
1090
1100
1102
721
2.73
833
3.15
927
3.51
1112
4.21
18
19
19
19
2.7
2.3
2.1
2.1
238
16.7
239
16.8
240
16.9
241
16.9
59
4.1
59
4.2
60
4.2
60
4.2
688
651
653
582
1336
1725
1715
2439
240
242
243
246
59
60
61
61
90/32
1089
1100
1110
1120
19
20
20
21
2.6
2.4
2.1
2.1
312
295
296
264
5.06
6.53
6.49
9.23
16.9
17.0
17.1
17.3
4.2
4.2
4.3
4.3
12,600 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,500 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
98 gal./h [AT 100ºF (38ºC) / WT 90ºF (32ºC)]
less than 10 PSIG
53
ENG.F-011.1.0205
7. KML-700MRJ
Specification Sheet
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
Performance Data Sheet
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
115/60/1
16.0 A (5 Min. Freeze AT 104°F / WT 80°F)
20 A
20 A
90/70°F
70/50°F
1260 (4.70)
1170 (3.78)
103 (16.0)
143 (19.3)
10.5 lbs. (4.8 kg) 480pcs.
Thermostat
TOTAL R404A, 11 lb. 7.4 oz. (5200g)
ICEMAKER, 7 lb. 8.6 oz. (3420g)
CONDENSER, 3 lb. 14.8 oz. (1780g)
AMBIENT TEMP.
(ºF/ºC)
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
80/27
90/32
100/38
70/21
80/27
90/32
100/38
70/21
80/27
90/32
100/38
713
705
143
134
131
117
50/10
1170
1190
1196
1195
204
217
220
223
52
54
54
55
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
18
19
19
19
2.4
2.4
2.3
2.2
323
320
0.54
0.51
0.50
0.44
14.3
15.2
15.5
15.7
3.7
3.8
3.8
3.8
WATER TEMP. (ºF/ºC)
70/21
643
292
633
287
1196
1231
1260
1264
131
0.50
116
0.44
103
0.39
101
0.38
19
20
21
22
2.3
2.2
2.2
2.1
220
15.5
242
17.0
260
18.3
264
18.6
54
3.8
57
4.0
60
4.2
61
4.3
602
565
123
111
96
90
239
259
278
295
57
60
63
65
90/32
1217
1243
1276
1290
21
22
23
25
2.3
2.2
2.1
2.1
273
256
0.46
0.42
0.36
0.34
16.8
18.2
19.6
20.7
4.0
4.2
4.4
4.6
11,200 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,500 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
ENG.F-011.1.0205
54
55
384±22
0 PSIG
412± 0 PSIG
327±22 PSIG
Cut-out
Cut-in
284±22 PSIG
Water-Cooled Model
22
Air-Cooled Model
* High-Pressure Switch
*
@
B. Wiring Diagram
1. KML-325M_J, KML-500M_J, KML-700M_J
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