Hoshizaki DKM-500BAJ Service Manual

Hoshizaki DKM-500BAJ Service Manual
Service Manual
Crescent Cube Icemaker / Dispenser
Models
DKM-500BAJ
DKM-500BWJ
hoshizakiamerica.com
Number: 73212
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 service should be undertaken until
the technician has thoroughly read this Service Manual. Failure to service and
maintain the appliance in accordance with this manual will adversely affect safety,
performance, component life, and warranty coverage. 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
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
Web Site: www.hoshizaki.com
NOTE: To expedite assistance, all correspondence/communication MUST include the
following information:
• Model Number
• Serial Number
• Complete and detailed explanation of the problem.
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 Models (BAJ)........................................................................................... 7
2. Water-Cooled Models (BWJ).................................................................................... 8
B. Water/Refrigeration Circuit Diagram............................................................................... 9
1. Air-Cooled Models (BAJ)........................................................................................... 9
2. Water-Cooled Models (BWJ).................................................................................. 10
II. Sequence of Operation and Service Diagnosis.................................................................11
A. Sequence of Operation Flow Chart...............................................................................11
B. Service Diagnosis........................................................................................................ 12
C. Control Board Check.................................................................................................... 19
D. Bin Control Check........................................................................................................ 20
E. Switches....................................................................................................................... 22
1. Control Switch......................................................................................................... 22
2. Service Switch........................................................................................................ 22
F. Float Switch Check and Cleaning................................................................................. 23
1. Float Switch Check................................................................................................. 23
2. Float Switch Cleaning............................................................................................. 24
G. Thermistor Check......................................................................................................... 25
H. Diagnostic Tables......................................................................................................... 26
III. Controls and Adjustments................................................................................................ 30
A. Control Board Layout................................................................................................... 31
B. LED Lights and Audible Alarm Safeties........................................................................ 32
C. Settings and Adjustments............................................................................................. 33
1. Default Dip Switch Settings..................................................................................... 33
2. Harvest Timer (S4 dip switch 1 & 2)....................................................................... 33
3. Pump-Out Timer (S4 dip switch 3 & 4)................................................................... 34
4. Pump-Out Frequency Control (S4 dip switch 5)...................................................... 34
5. Harvest Pump Time (S4 dip switch 6)..................................................................... 35
6. Harvest Pump Timer Operation (S4 dip switch 7)................................................... 35
7. Factory Use (S4 dip switch 8)................................................................................. 36
8. Freeze Timer (S4 dip switch 9 & 10)....................................................................... 36
9. Float Switch Selector (S5 dip switch 1).................................................................. 36
10. Refill Counter (S5 dip switch 2 and 3)................................................................... 36
11. Minimum Harvest Time (S5 dip switch 4).............................................................. 37
12. Anti-Slush (S5 dip switch 5).................................................................................. 37
3
IV. Refrigeration Circuit and Component Service Information.............................................. 38
A. Refrigeration Circuit Service Information..................................................................... 38
B. Component Service Information................................................................................... 41
C. Water Regulating Valve Adjustment (water-cooled model)........................................... 41
V. Maintenance..................................................................................................................... 42
VI. Preparing the Appliance for Periods of Non-Use............................................................. 43
VII. Disposal.......................................................................................................................... 45
VIII. Technical Information..................................................................................................... 46
A. Specification and Performance Data Sheets................................................................ 46
1. DKM-500BAJ.......................................................................................................... 46
2. DKM-500BWJ......................................................................................................... 47
B. Wiring Diagram ............................................................................................................ 48
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.
• The appliance 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 fuse, damage to existing
wiring, or component failure. This could lead to heat generation or fire.
• THE APPLIANCE MUST BE GROUNDED: The appliance is equipped with a
NEMA 5-20 three‑prong grounding plug
to reduce the risk of potential shock
hazards. It must be plugged into a properly grounded, independent 3-prong wall
outlet. If the outlet is a 2-prong outlet, it is your personal responsibility to have
a qualified electrician replace it with a properly grounded, independent 3-prong
wall outlet. Do not remove the ground prong from the power cord and do not use
an adapter plug. Failure to properly ground the appliance could result in death or
serious injury.
• Do not use an extension cord.
• To reduce the risk of electric shock, do not touch the control switch, service switch,
or plug with damp hands. Make sure the control switch is in the "OFF" position
before plugging in or unplugging the appliance.
• Do not use an appliance with a damaged power cord. The power cord should not
be altered, jerked, bundled, weighed down, pinched, or tangled. Such actions could
result in electric shock or fire. To unplug the appliance, be sure to pull the plug, not
the cord, and do not jerk the cord.
5
WARNING, continued
• Do not make any alterations to the appliance. Alterations could result in electric
shock, injury, fire, or damage to the appliance.
• 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.
• Children should be properly supervised around the 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.
NOTICE
• Follow the water supply, drain connection, and maintenance instructions 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). If the normal
operating ambient temperature is above 90°F (32°C), the compressor insulation
cover must be removed.
• Do not leave the appliance on during extended periods of non-use, extended
absences, or in sub-freezing temperatures. To properly prepare the appliance for
these occasions, follow the instructions in "IV. Preparing the Appliance for Periods
of Non-Use."
• Do not place objects on top of the appliance.
• The storage bin is for ice use only. Do not store anything else in the storage bin.
6
I. Construction and Water/Refrigeration Circuit Diagram
A. Construction
1. Air-Cooled Models (BAJ)
Mechanical Bin
Control
Bin Cover
Wash Valve
Hot Gas Valve
Spray Tubes
Inlet Water Valve
Drain Valve
Water Supply
Inlet
Expansion Valve
Water Pump
Float Switch
Ice Cube Guide
Bin
Agitator
Shutter
Chain
Solenoid
Assembly
Dispense Switch
Spout
Extension
Condenser
Gear Motor
Assembly
Drier
Dispense Switch
Connector
Compressor
Condenser
Fan Motor
Front Panel
Drain Pan
7
Strainer
Control
Switches
Control Box
2. Water-Cooled Models (BWJ)
Mechanical Bin
Control
Bin Cover
Wash Valve
Hot Gas Valve
Spray Tubes
Inlet Water Valve
Drain Valve
Strainer
Expansion Valve
Water Supply
Inlet
Water Pump
Float Switch
Ice Cube Guide
Bin
Agitator
Shutter
Chain
Solenoid
Assembly
Dispense Switch
Spout
Extension
Condenser
Line Valve
Drier
Gear Motor
Assembly
Water
Regulator
Compressor
Dispense Switch
Connector
Control
Switches
Drain Pan
Front Panel
8
Control Box
B. Water/Refrigeration Circuit Diagram
1. Air-Cooled Models (BAJ)
9
2. Water-Cooled Models (BWJ)
10
11
Comp energized
FM 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
To 1 above
MBC closed
(MBC actuator paddle disengaged)
Green "BC CLOSED" LED on
Yellow "BC OPEN" LED off
Icemaker starts at
"1. 1-Minute Fill Cycle."
3. Ice Level Lowered
The "WASH" position on the control switch is used when cleaning and sanitizing the icemaker. When in the "WASH" position, power is
supplied to the pump motor. With the cleaning valve closed, the cleaner and sanitizer flow over the outside of the evaporator plate assembly.
With the cleaning valve open, the cleaner and sanitizer flow over both the outside and the inside of the evaporator plate assembly.
Note: Close the cleaning valve after cleaning and sanitizing are complete, otherwise the icemaker will not restart when the control switch is
placed in the "ICE" position.
Yellow "BC OPEN" LED continues. All
components de‑energized.
All components
de-energized.
2. Icemaker Off
Comp continues
FMR continues
HGV energized
PM de-energizes for 2 sec.,
then energizes for 10/20 sec.
FM de-energized
LLV de-energized
Components Energized when the Control Switch is in the "WASH" Position
MBC open (MBC actuator paddle engaged)
Green "BC CLOSED" LED off
Yellow "BC OPEN" LED on
Legend:
Comp–compressor
FM–fan motor
FS–float switch
HGV–hot gas valve
LLV–liquid line valve
MBC–mechanical bin control
PM–pump motor
WV–inlet water valve
MBC Operation
FS in control
FS opens or
freeze timer
terminates
• Factory set for every
10th cycle
• Pump motor stops for
2 sec., then reverses
for 10/20 sec.
(S4 dip switch 3 & 4)
4. Pump-Out Cycle
Comp continues Anti-Slush
Thermistor temperature
FMR continues
reaches 36°F (2.2°C)
FM energized
(5.8 kΩ).
LLV energized
PM de-energized for
PM energized
10 sec.
HGV de-energized
FS closed
5-min. minimum
freeze timer in
control
• Minimum freeze time: 5 min.
• Maximum freeze time: freeze timer
setting (S4 dip switch 9 & 10)
3. Freeze Cycle
Shutdown Delay:
• Fill Cycle–15 sec. after activation.
• Harvest Cycle–At the end of the harvest cycle, or up to 15 sec. into the
freeze cycle if activated at the end of the harvest cycle.
• Freeze Cycle–15 sec. after activation if activated at least 15 sec. before the 5-min. short cycle protection timer terminates.
Otherwise, at the end of the next harvest cycle.
1. Bin Full
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
If FS is open, Comp stops and cycle returns to 1-min. fill.
FS open
WV energized
FS check
1. 1-Minute
Fill Cycle
Shutdown
and Restart
Startup
Cycle
Steps
"J" Control Board With Harvest Pump Timer Operation Sequence Flow Chart
II. Sequence of Operation and Service Diagnosis
A. Sequence of Operation 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.
12
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 full bin), check MBC. Move ice away
from MBC actuator paddle. If yellow "BC OPEN" LED stays on, see "II.D. Mechanical
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,
remove ice from BC. If no ice is around BC and yellow "BC OPEN" LED is on,
see "II.D. Mechanical Bin Control Check."
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 pink (P) wire to neutral (W) then HPS black (BK) wire to neutral (W). If 115VAC
is present at HPS pink (P) wire and not at HPS black (BK) wire, HPS is open.
See HPS Diagnosis below. If 115VAC is present at HPS black (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 and the FM is operating correctly. 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, 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, Comp, and HGV 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.
13
5a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp,
HGV, X12, and X10 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.
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, and X12 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) Contorl 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 X12 relay terminal #8 (P) to terminal #7 neutral (W). If 115VAC is present, check
for 115VAC at X12 relay terminal #6 (DBU) to neutral (W) and terminal #4 (Y) to
neutral (W). If 115VAC is present on terminal #6 (DBU) and not on terminal #4 (Y),
replace X12 relay.
d) Pump Motor Diagnosis: If 115VAC is present on X12 terminal #4 (Y) to neutral (W)
and PM is not energized, check PM capacitor and motor winding continuity.
14
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 and PM continue. FM and LLV (if applicable)
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 and PM continue. Confirm that FM and
LLV (if applicable) energize. Confirm WRV (if applicable) 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), LLV (if applicable) and FM energize, TXV operating correctly, WRV
(if applicable) opens, Comp is efficient, and refrigerant charge is correct. See "VIII.A.
Specification and Performance Data Sheet."
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.B.
Performance Data Sheets."
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).
15
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 CB K1 #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 and LLV Diagnosis: If FM or LLV (if applicable) 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 LLV, check coil voltage and continuity.
f) Refrigerant Pressures and TXV Diagnosis: If evaporator is still not cooling, check
refrigerant pressures. See "VIII.B. Performance Data Sheets."
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.B.
Performance Data Sheet." 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.B. Performance Data Sheet."
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.
16
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 continues, HGV energizes, LLV (if applicable) de-energizes. NOTICE! S4 dip
switch 3 & 4 must not be set to 3 off and 4 on. Otherwise, LED 4 truns on
energizing WV, X11, and X10 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 pump-out timer terminates, pumpout 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 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 LLV (if applicable) de-energizes. If LLV (if applicable) is
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. If 115VAC is
present at CB K1 #5 (DBU) and PM and DV are not energized, check 115VAC at CB
K1 #2 (P) to neutral (W). If LED 2 is on and 115VAC is not present at CB K1 #2 (P),
replace CB.
c) X12 Relay PM Diagnosis: If 115VAC is present at CB K1 #2 (P) and PM and DV
are not energized, check for 115VAC at X12 relay #8 (P) to neutral (W). If 115VAC
is not present, check wiring connections from CB. If 115VAC is present, and X12 is
de‑enrgized, check relay coil continuity. Replace as needed.
(1) For PM and X12 Relay; Check for 115VAC at X12 terminal #6 (DBU) to neutral
(W). If 115VAC is not present, see "CB Diagnosis" above. Next, check for 115VAC
at X12 terminal #4 (Y) to neutral (W). If 115VAC is not present, replace X12 relay
(contacts sticking). If 115VAC is present and PM is not energized, check PM
capacitor, motor winding, and impeller for binding.
17
(2) For DV, X12 and X12 Relays; If PM is energized and DV is de-energized, confirm
X10 relay is de‑energized. If X10 relay is energized, check X11 contacts for sticking.
Replace as needed. If X10 relay is de-energized and DV is de-energized, check for
115VAC at X10 terminal #1 (DBU) to neutral (W). If 115VAC is not present, confirm
115VAC at X10 terminal #5 (DBU). If 115VAC is present at X10 terminal #5 (DBU)
and not at X10 terminal #1 (DBU), replace X10 relay (contacts sticking open). If
115VAC is present at X10 terminal #1 (DBU), check for 115VAC at X12 #3 (W/
BU) to neutral (W). If 115VAC is not present at X12 #3 (W/BU) and X12 relay is
energized, replace X12 relay (contacts sticking open). If 115VAC is present at X12
#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 BC is satisfied or power is switched off. The
appliance always restarts at the 1-min. fill cycle.
9) Shutdown
Mechanical Bin Control:
See "II.D.2. Mechanical Bin Control Check."
Legend: BC–bin control; CB–control board; Comp–compressor; DV–drain valve;
FM–fan motor; FS–float switch; HGV–hot gas valve; HPS–high-pressure switch;
LLV–liquid line valve; MBC–mechanical bin control; PM–pump motor;
TXV–thermostatic expansion valve; WRV–water regulating Valve;
WV–inlet water valve
18
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 terminal #2 (BK) and control switch terminal
#3 (P) to neutral (W). If 115VAC is present at control switch terminal #2 (BK) and not
at control switch terminal #3 (P), replace control switch. If 115VAC is present at control
switch terminal #3 (P), check for 115VAC at HPS (BK) 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
Correct LED
Board 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
19
D. Bin Control Check
1. Mechanical Bin Control Check
This appliance uses a lever-actuated proximity switch to control the ice level in the
storage bin. No adjustment is required.
To check MBC, 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
MBC.
4) Check MBC wire harness connections. See Fig. 1.
MBC Connector
(to control
board K4 (red)
connector)
5) Disconnect MBC connector from CB K4 connector.
6) Check for continuity across the wires of
MBC connector. When the actuator paddle
is not engaged, MBC switch is closed.
If open, check that the wire harness
connector is properly connected and that
the actuator paddle is not sticking. Clean if
necessary. See "II.D.2.b) Mechanical Bin
Control Cleaning." If MBC switch still reads
open, replace MBC.
MBC
MBC Wire
Harness (white)
Connector
Actuator
Paddle
Fig. 1
7) Press and hold the actuator paddle; check for continuity across the wires of MBC
connector. When the actuator paddle is engaged, MBC switch is open. If closed, check
that the actuator paddle is not restricted. Clean if necessary. See "II.D.2.b) Mechanical
Bin Control Cleaning." If MBC switch still reads closed, replace MBC.
8) Reconnect MBC connector to CB K4 connector, then move the control switch to the
"ICE" position. Turn on the power supply.
9) Check that CB green "BC CLOSED" LED is on.
10) Allow the icemaker to cycle on. Press and hold the actuator paddle. CB yellow
"BC OPEN" LED should turn on and the icemaker should shut down according to the
chart below. If it does not, replace CB.
Cycle at
Shutdown
Mechanical Bin
Control Activation
Fill Cycle
15 sec. after activation.
Harvest Cycle
At the end of the harvest cycle, or up to 15 sec. into the freeze cycle if activated at the
end of the harvest cycle.
Freeze Cycle
15 sec. after activation if activated at least 15 sec. before the 5-min. short cycle
protection timer terminates. Otherwise, at the end of the next harvest cycle.
Legend: MBC–mechanical bin control; CB–control board
20
2. Mechanical Bin Control Cleaning
Scale may build up on MBC. Scale can cause the actuator paddle and magnet to stick. In
this case, MBC should be cleaned.
WARNING
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 dispense unit/ice storage bin.
1) Turn off the power supply.
2) Remove the front panel, then move the control switch to the "OFF" position.
3) Clear any ice away from MBC.
4) Disconnect MBC connector from CB K4 connector, then remove MBC from the
icemaker.
5) Remove the actuator paddle from the switch mount. See Fig. 2.
6) Wipe down MBC with a mixture of 1 part of Hoshizaki "Scale Away" and 25 parts of
warm water. Rinse the parts thoroughly with clean water.
7) Reassemble MBC and replace it in its correct position.
Note: If the magnet was removed for cleaning, be sure to replace it in its correct
position.
8) Reconnect MBC connector to CB K4 connector, then move the control switch to the
"ICE" position.
9) Replace the control box cover in its correct position.
10) Turn on the power supply to start the automatic icemaking process.
11) Replace the front panel in its correct position.
Legend: MBC–mechanical bin control
KM-901M_H/3
MBC Bracket
MBC Wire
Harness (white)
Connector
Switch Mount
Actuator
Paddle
Bin Control Proximity
Switch Closed
(calling for ice)
MBC Connector
(to control
board K4 (red)
connector)
Bin Control
Proximity Switch
Open (bin full,
icemaker off or
shutting down)
Fig. 2
21
Magnet
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.
22
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. Disconnect the dispense solenoid wire harness and set front
panel aside. Move the control switch to the "SERVICE" position, then move the service
switch to the "DRAIN" position.
2) Allow the water to drain from the water tank. Move the control switch to the "OFF"
position, then 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 connector, then replace the control box cover in its
correct position.
7) Move the control switch to the "ICE" position. 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. Reconnect the dispense solenoid
wire harness, then replace the front panel in its correct position. If the initial harvest
cycle does not begin, continue to step 8.
8) Turn off the power supply.
9) Move the control switch to the "OFF" position.
10) Remove the control box cover.
11) Disconnect FS connector from CB K5 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
necessary.
13) After repair is complete, replace the control box cover, move the control switch to the
"ICE" position. Reconnect the dispense solenoid wire harness, then replace the front
panel in its correct position. Next, turn on the power supply.
Legend: CB–control board; FS–float switch
23
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. Disconnect the dispense solenoid wire harness and set front
panel aside. Move the control switch to the "SERVICE" position, then move the service
switch to the "DRAIN" position.
2) Allow the water to drain from the water tank. Move the control switch to the "OFF"
position, then turn off the power supply.
3) Remove the 3 FS assembly mounting screws and remove FS assembly from the water
tank. See Fig. 3.
5) 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. 4.
6) Wipe down FS mounting bracktes, housing, shaft, float, and retainer rod with a mixture
of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Clean the inside of the vent
hose with cleaning solution. 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) Reconnect the dispense solenoid wire harness and 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
Mounting
Brackets
FS Assembly
Mounting Screws
Vent Hose
Water Tank
Float Switch
Housing
Shaft
Float
Retainer Rod
Fig. 3
Foat Switch Assembly
Fig. 4
24
G. Thermistor Check
To check thermistor resistance, follow the steps below.
1) Turn off the power supply.
2) Remove the front panel. Disconnect the dispense solenoid wire harness and set front
panel aside. 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) Reconnect the dispense solenoid wire harness and 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
25
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.
3. Fuse (control box)
a) Blown or tripped.
5. Control Switch
a) In "OFF" or "SERVICE" position.
b) Bad contacts.
6. High-Pressure Switch
a) Dirty condenser.
b) Fan motor not operating.
c) Refrigerant overcharged.
d) Bad contacts.
e) Refrigerant lines or components plugged.
7. Control Transformer
(115VAC/10.5VAC)
a) Coil winding open or shorted.
8. Control Board
See "II.C. Control Board Check"
a) In alarm.
b) Yellow "BC OPEN" LED on (bin full).
c) Defective.
9. Mechanical Bin Control
See "II.D. Bin Control Check"
a) Tripped with bin filled with ice.
b) Actuator does not move freely.
c) Defective.
10. Water Supply
a) Water supply off or improper water pressure.
b) External water filters clogged.
11. Inlet Water Valve
a) Screen or orifice clogged.
b) Coil winding open.
c) Water valve open in freeze cycle.
12. Float Switch
See "II.E. Float Switch Check
and Cleaning"
a) Float does not move freely.
13. 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.
e) Defective.
14. Hot Gas Valve
a) Closed in harvest cycle.
b) Open in freeze cycle.
15. Thermistor
See "II.F. Thermistor Check"
a) Loose, disconnected, or defective.
16. Pump Motor
a) Motor winding open.
b) Bearing worn out or locked rotor.
c) Defective capacitor.
d) Mechanical seal worn out.
17. Thermostatic Expansion Valve
a) Bulb loose.
b) Operating erratically.
26
No Ice Production - Possible Cause
18. Liquid Line Valve
a) Closed in freeze cycle.
b) Open in harvest cycle.
19. Fan Motor
a) Motor winding open.
b) Bearing worn out or locked rotor.
c) Defective capacitor.
20. Water System
(drain valve, bypass valve)
a) Water leaks causing short freeze time or freeze up.
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.
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.
9. Bin Control
See "II.D. Bin Control Check"
a) Actuator does not move freely.
b) Defective.
b) Defective.
b) Harvest pump timer (S4 dip switch 7) not in factory default position.
c) Defective.
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.
27
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.
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.
b) Out of position.
3. Refrigerant Charge
a) Low.
4. Water Supply
a) Low water pressure.
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.
8. Inlet Water Valve
a) Screen or orifice clogged.
9. Compressor
b) Defective.
a) Inefficient or off.
10. Liquid Line Valve
a) Erratic or open.
11. Thermostatic Expansion Valve
a) Defective.
28
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.
3. Inlet Water Valve
a) Leaking by.
b) Float sticking.
c) Defective switch.
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).
7. Refrigerant Charge
a) Low.
8. Thermostatic Expansion Valve
a) Bulb loose.
b) Defective.
b) Defective.
9. Compressor
a) Inefficient or off.
10. Pump Motor
a) RPM too slow.
11. Liquid Line Valve
a) Erratic or restricted.
29
III. Controls and Adjustments
• A Hoshizaki exclusive control board is employed in KM 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, and float switch.
• Do not short out power supply to test for voltage.
• Always replace the whole control board assembly if it goes bad.
30
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
• K3 (white) Connector
Thermistor
(harvest control and
high temperature safety)
• Bin Control Switch
Open LED (yellow)
(mechanical bin
control application only)
• Alarm Buzzer
• K4 (red) Connector
Mechanical Bin Control or
K4 Jumper (thermostatic
bin control application)
• S5 Dip Switch
• Ext. Harvest LED
(blue) (lights when
water line thermistor
initiates extended
harvest) Not used
this model
• K5 (black) Connector
Float Switch
(water level)
• POWER OK LED
(red) (lights when
10.5VAC is supplied
to K2 connector)
• Part Number
• K1 Connector
Pins #1 through #10
#1, 9 Compressor Relay
#2 Hot Gas Valve, X12 Relay
#3 Fan Motor
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
• Relay LEDs
(4) (indicate which
relays are energized
and which K1
connector pins are
energized
• 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
31
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.
Time LEDs are On
Max.
Avg.
1-Minute Fill Cycle
4
WV
1 minute
Harvest Cycle
1, 4, 2
Comp, HGV, WV
2 minutes 20 minutes 3 to 5 minutes
Harvest Pump Timer 1, 3, 2
Comp, HGV, PM
0 seconds 50 seconds harvest pump timer
setting
Freeze Cycle
1
Comp, FM, PM, LLV
5 minutes freeze timer 30 to 35 minutes
setting
Pump-Out Cycle
1, 4*, 3, 2 Comp, HGV, PM, WV* 10 seconds 20 seconds *pump‑out timer
setting
Sequence Step
LED
Energized
Components
Min.
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; FM–fan motor; FS–float switch; HGV–hot gas valve;
LLV–liquid line valve; PM–pump motor; TXV–thermostatic expansion valve;
WRV–water regulating valve; WV–inlet water valve
32
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
All Models
2
3
4
5
6
7
8
9
10
OFF OFF OFF OFF OFF OFF ON OFF OFF OFF
S5 Dip Switch (Do Not Adjust)
"J" Control Board
Dip Switch No.
2
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 Time (7) (Do Not Adjust)
ON
1 2 3 4 5 6 7 8 9 10
ON
S4 Dip Switch
"J" Control Board
Harvest Pump Timer (6) (Do Not Adjust)
Pump-Out Frequency Control (5)
1 2 3 4 5
All Models
1
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
33
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. The pump motor drains the water tank for the time
determined by the pump-out timer. The pump‑out timer also acts in place of the harvest
timer during cycles with a pump‑out. The pump-out timer is factory set, and generally no
adjustment is required. However, where water quality is bad and the icemaker needs a
longer pump-out time, the pump‑out timer can be adjusted. The pump‑out timer control
can be set to pump-out for 10 or 20 sec.
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
2, 5, or 10 cycles.
The first pump-out is dependent on S4 dip switch 5. See the table below.
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
34
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 Time Operation (S4 dip switch 7)
S4 dip switch 7 is used for harvest pump timer operation.
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 inlet water valve is open during harvest for a
maximum of 6 minutes or the length of harvest minus 0 or 50 sec. (determined by the
harvest pump time 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.C. Wiring Diagrams." 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 and X12 relay remains energized through the pink (P) wire. Next, LED 3 turns on
and control board K1 connector pin #5 (DBU) wire energizes, energizing the pump motor
through the X12 relay for the last 50 sec. of harvest.
"J" Control Board
S4 Dip Switch Setting
No. 7
Pump Motor
Time (sec.)
OFF
Disabled
ON
Enabled
35
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
36
11. Minimum Harvest Time (S5 dip switch 4)
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside of the factory
default setting may result in damage to the appliance.
S5 Dip Switch Setting
No. 4
Minimum Harvest Time
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. Adjustments outside of the factory
default setting may result in damage to the appliance and may adversely affect
performance and warranty coverage.
S5 Dip Switch Setting
No. 5
Anti-Slush
OFF
Disabled
ON
Enabled
37
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.
38
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.
39
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
ARI 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.
40
B. Component Service Information
NOTICE
When replacing a component listed below, see the notes to help ensure proper
operation.
Component
Compressor
Notes
Install a new start capacitor, run capacitor, and start relay.
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.
• Use copper tube of the same diameter and length when replacing valve lines.
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.
• 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. 5. 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.
41
Fig. 5
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.
Underside of
Wipe down with a clean cloth and warm water.
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
42
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.
• To prevent damage to the water pump, do not operate the appliance with the
control switch in the "WASH" position when the water tank is empty.
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. Disconnect the dispense solenoid
wire harness and set the front panel aside.
2) Move the control switch on the control box to the "OFF" position.
3) Close the icemaker water supply line shut-off valve and open the icemaker water supply
line drain valve.
4) Allow the line to drain by gravity.
5) Attach a 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. Make 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 the compressed air or carbon dioxide supply.
2. Remove the water from 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) Reconnect the dispense solenoid wire harness and replace the front panel in its correct
position.
7) Turn on the power supply and dispense all ice from the icemaker. After dispensing all of the
ice, turn off the power supply.
8) Close the icemaker water supply line drain valve.
43
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. Disconnect the dispense
solenoid wire harness and set front panel aside. Remove the left 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 left side panel in its correct position, then reconnect the dispense solenoid
wire harness and replace the front panel in its correct position.
44
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.
45
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. DKM-500BAJ
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
APPROXIMATE STORAGE CAPACITY
APPROXIMATE ICE DISPENSE RATE
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
2
PSIG kg/cm G
SUCTION PRESSURE
PSIG
2
kg/cm G
115/60/1
13.5 A ( 5 Min. Freeze AT 104°F / WT 80°F)
20 A
20 A
90/70°F
70/50°F
1240(5.56)
1130(4.98)
89(16.6)
202(37.0)
7.2 lbs. (3.3 kg) 360pcs.
140 lbs. (64 kg)
13 lbs/min. (6 kg/min)
Proximity Switch with Delay
R404A, 1 lb. 12.2 oz. (800g)
AMBIENT TEMP.
(ºF/ºC)
70/21
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
545
540
202
176
169
133
242
258
263
270
51
53
53
53
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
50/10
1130
1155
1162
1155
15
16
16
16
3.5
3.2
3.1
2.6
247
245
0.76
0.67
0.64
0.50
17.0
18.1
18.5
19.0
3.6
3.7
3.7
3.7
WATER TEMP. (ºF/ºC)
70/21
542
246
533
242
1162
1205
1240
1241
169
0.64
125
0.47
89
0.34
88
0.33
16
17
18
18
3.1
2.6
2.1
2.1
263
18.5
290
20.4
313
22.0
321
22.6
53
3.7
56
3.9
58
4.1
58
4.1
536
523
156
130
86
84
295
324
347
378
54
56
59
59
90/32
1177
1203
1245
1250
17
18
19
20
2.9
2.6
2.1
2.1
243
237
0.59
0.49
0.33
0.32
20.7
22.8
24.4
26.6
3.8
3.9
4.1
4.1
9,100 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,700 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
46
2. DKM-500BWJ
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
APPROXIMATE STORAGE CAPACITY
APPROXIMATE ICE DISPENSE RATE
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
2
PSIG kg/cm G
SUCTION PRESSURE
PSIG
2
kg/cm G
115/60/1
12 A ( 5 Min. Freeze AT 104°F / WT 80°F)
20 A
20 A
90/70°F
70/50°F
1000(4.79)
960(4.26)
90(18.0)
126(23.4)
515(103)
266(49)
7.2 lbs. (3.3 kg) 360pcs.
140 lbs. (64 kg)
13 lbs/min. (6 kg/min)
Proximity Switch with Delay
R404A, 1 lb. 2 oz. (510g)
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
540
531
528
523
393
440
455
552
278
280
280
281
53
53
54
54
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
WATER FLOW FOR CONDENSER
PRESSURE DROP OF COOLING WATER LINE
50/10
960
969
972
973
18
18
18
18
2.6
2.5
2.4
2.3
245
241
240
237
1.49
1.67
1.72
2.09
19.5
19.7
19.7
19.8
3.7
3.8
3.8
3.8
WATER TEMP. (ºF/ºC)
70/21
528
240
513
233
500
227
495
225
972
987
1000
1002
455
1.72
537
2.03
605
2.29
628
2.38
18
19
19
19
2.4
2.2
2.1
2.0
280
19.7
283
19.9
285
20.0
286
20.1
54
3.8
54
3.8
55
3.9
55
3.9
509
492
479
460
549
635
704
794
283
286
289
292
55
55
56
57
90/32
983
996
1010
1020
19
19
20
21
2.4
2.3
2.0
2.0
231
223
217
209
2.08
2.41
2.66
3.01
19.9
20.1
20.3
20.5
3.8
3.9
3.9
4.0
7,700 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
30 gal./h [AT 100ºF (38ºC) / WT 90ºF (32ºC)]
less than 10 PSIG
ENG.F-011.1.0205
47
48
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. DKM-500B_J
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