Hoshizaki KM-161BAJ Service Manual

Hoshizaki KM-161BAJ Service Manual
Service Manual
Self-Contained Crescent Cuber
Models
KM-81BAJ
KM-116BAJ
KM-161BAJ, BWJ
hoshizakiamerica.com
Number: 73240
Issued: 8-20-2019
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
3. Icemaking Compartment.......................................................................................... 9
B. Water/Refrigeration Circuit Diagram............................................................................. 10
1. KM-81BAJ, KM-116BAJ.......................................................................................... 10
2. KM-161BAJ.............................................................................................................11
3. KM-161BWJ........................................................................................................... 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.................................................................................................... 21
D. Bin Control Check........................................................................................................ 22
E. Float Switch Check and Cleaning................................................................................ 25
F. Thermistor Check.......................................................................................................... 27
G. Switch.......................................................................................................................... 27
H. Diagnostic Tables......................................................................................................... 28
I. Freeze-Up Check List.................................................................................................... 32
III. Controls and Adjustments................................................................................................ 33
A. Control Board Layout................................................................................................... 34
B. LED Lights and Audible Alarm Safeties........................................................................ 35
C. Settings and Adjustments............................................................................................. 36
1. Default Dip Switch Settings..................................................................................... 36
2. Harvest Time (S1 dip switch 1 & 2)........................................................................ 37
3. Pump-Out Time/Harvest Time During Pump-Out (S1 dip switch 3 & 4).................. 37
4. Pump-Out Frequency Control (S1 dip switch 5 & 6)............................................... 38
5. Harvest Pump Time Duration (Harvest Assist) (S1 dip switch 7 & 8)...................... 38
6. Freeze Timer (S1 dip switch 9 & 10)....................................................................... 39
7. Pump-Out/Drain Selector (S2 dip switch 1)............................................................. 39
8. Harvest Promotion Control (S2 dip switch 2).......................................................... 39
9. Minimum Harvest Time (S2 dip switch 3)............................................................... 40
10. Harvest Completion Detection Control (S2 dip switch 4)...................................... 40
11. Overfreeze Detection Control (S2 dip switch 5)..................................................... 41
12. Slush Control (S2 dip switch 6)............................................................................. 42
3
IV. Refrigeration Circuit and Component Service Information.............................................. 43
A. Refrigeration Circuit Service Information..................................................................... 43
B. Component Service Information................................................................................... 46
C. Water Regulating Valve Adjustment (water-cooled model)........................................... 46
V. Maintenance..................................................................................................................... 47
VI. Preparing the Appliance for Periods of Non-Use............................................................. 48
VII. Disposal.......................................................................................................................... 50
VIII. Technical Information..................................................................................................... 51
A. Specification and Performance Data Sheets................................................................ 51
1. KM-81BAJ............................................................................................................... 51
2. KM-116BAJ............................................................................................................. 52
3. KM-161BAJ............................................................................................................. 53
4. KM-161BWJ............................................................................................................ 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.
• 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 5-15 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.
• The GREEN ground wire in the factory-installed power cord is connected to the
appliance. If it becomes necessary to remove or replace the power cord, be sure
to connect the power cord's ground wire.
• To reduce the risk of electric shock, do not touch the control 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 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.
• Be careful not to pinch fingers when opening and closing the door. Be careful when
opening and closing the door when children are in the area.
• 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
• Protect the floor when moving the appliance to prevent damage to the floor.
• When making water supply or drain line repairs, follow the requirements found in the
instruction manual to reduce the risk of costly water damage.
• In areas where water damage is a concern, confirm appliance is installed in a
contained area with a floor drain.
• Confirm the appliance is 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 water collects in the bin and will not drain, turn off the appliance and close the
water supply line shut-off valve.
• If water seeps from the base of the appliance, turn off the appliance and close the
water supply line shut-off valve. Failure to do so could lead to costly water damage.
• 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 "VI. Preparing the Appliance for Periods
of Non‑Use."
• Keep ventilation openings, in the appliance enclosure or in the built-in structure,
clear of obstruction.
• Do not place more than 33 lb. (15 kg) on the top panel of the appliance.
• The ice storage bin is for ice use only. Do not store anything else in the ice storage
bin.
6
I. Construction and Water/Refrigeration Circuit Diagram
A. Construction
1. Air-Cooled Models (BAJ)
Top Panel
Spray Tube
Evaporator
Separator
Door
Water Supply
Tube
Front
Panel
Water Tank
Louver
Control Box
Control Switch
Condenser
Air Filter
Front View
Fan Motor
Hot Gas Valve
Compressor
Thermistor
Cleaning
Valve
Inlet
Water
Valve
Rear Panel
Pipe Cover
Rear Cover
Water
Pump
Power
Supply
Cord
Drain Valve
Rear View
Thermostatic
Expansion Valve
Drier
Bin Control
Float Switch
With Tank Removed
7
2. Water-Cooled Models (BWJ)
Top Panel
Door
Spray Tube
Evaporator
Separator
Water Supply
Tube
Water
Tank
Front Panel
Louver
Control Switch
Control Box
Front View
Air Filter
Condenser
Fan Motor
Compressor
Cleaning Valve
Thermistor
Inlet
Water
Valve
Water
Pump
Rear Panel
Pipe Cover
Rear Cover
Thermostatic
Expansion
Valve
Drain Valve
Hot Gas
Valve
Power
Supply
Cord
Rear View
Drier
Water Regulating Valve
Float Switch
Bin Control
With Tank Removed
8
3. Icemaking Compartment
Inlet Water Valve
Cleaning Valve
Spray Tube
Water Supply Pipe
Evaporator
Separator
Cube Guide
Float Switch
Water Tank
9
Water Pump
B. Water/Refrigeration Circuit Diagram
1. KM-81BAJ, KM-116BAJ
Water Supply
Capillary Tube
Accumulator
Inlet Water Valve
Spray Tube
Cleaning Valve
Thermistor
Pump Motor
Evaporator
Water Tank
Float Switch
Drain Valve
Drain Outlet
Heat Exchanger
Suction Line
Drier
Condenser
Discharge
Line
Strainer
Fan
Compressor
Water Circuit
Refrigeration Circuit
10
Hot Gas
Valve
2. KM-161BAJ
Water Supply
Inlet Water Valve
Thermostatic
Expansion Valve
Cleaning Valve
Spray Tube
Thermistor
Evaporator
Water Tank
Drain Valve
Pump Motor
Float Switch
Drain Outlet
Hot Gas
Valve
Heat Exchanger
Compressor
Suction Line
Strainer
Fan
Discharge
Line
Condenser
Water Circuit
Refrigeration Circuit
11
Drier
High Pressure
Switch
3. KM-161BWJ
Water Supply
Inlet Water Valve
Thermostatic
Expansion Valve
Cleaning Valve
Spray Tube
Thermistor
Evaporator
Water Tank
Drain Valve
Pump Motor
Float Switch
Drain Outlet
Hot Gas
Valve
Heat Exchanger
Compressor
Suction Line
Strainer
Discharge
Line
Drier
Condenser
High Pressure
Switch
Water Circuit
Refrigeration Circuit
Water Regulating Valve
12
13
Comp energized
HGV energized
WV energized
DV de-energized
FS closed
Thermistor
in control
FS check
5-min. min.
freeze timer
FS opens or Comp energized
freeze timer HGV energized
terminates DV energized
PM de-energizes for 2 sec.,
then restarts for 10/20 sec.
FM de-energized
FS in
control
• Factory set for every
10th cycle
(S1 dip switch 5 & 6)
• Pump motor stops for
2 sec., then restarts
for 10/20 sec.
(S1 dip switch 3 & 4)
4. Pump-Out Cycle
The "WASH" position on the control switch is used when cleaning and sanitizing the unit. When in the "WASH" position, power is supplied
to the pump motor. With the cleaning valve closed, the cleaner and sanitizer flow over the outside of the evaporator plate assembly. With the
cleaning valve open, the cleaner and sanitizer flow over both the outside and the inside of the evaporator plate assembly.
Note: Close the cleaning valve after cleaning and sanitizing are complete, otherwise the unit will not restart when the control
switch is placed in the "ICE" position.
Slush Control
Thermistor
Comp energized
reaches 41°F
FM energized
(5°C 4.8 kΩ)
PM energized
PM de-nergizes
HGV de-energized
for 10 sec. then
energizes
FS closed
Thermistor
reaches 36°F (2°C)
5-min. min. freeze
timer starts
• Min. freeze time: 5 min.
• Max. freeze time: freeze timer setting
(S1 dip switch 9 & 10)
3. Freeze Cycle
Components Energized when the Control Switch is in the "WASH" Position
FS open
Thermistor temperature reaches
48°F (9°C) (3.9 kΩ or less). Harvest
timer starts.
PM energized
WV de-energized
1 to 3-min. harvest timer in
control (S1 dip switch 1 & 2)
Harvest Pump
Timer
30 sec. or
50 sec.
• WV time: 6 min. or the length of harvest minus
50 sec. (KM-81, 161) or 10 sec. (KM-116) (S1
dip switch 7), whichever is shorter. Do not adjust
S1 dip switch 7 out of the factory position.
• Max. 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
1. Operation Flow Chart
Legend:
Comp–compressor
DV–drain valve
FM–fan motor
FS–float switch
HGV–hot gas 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
BC Operation
14
Legend:
BC–bin control
DV–drain valve
FS–float switch
PM–pump motor
2 sec. after all components
de-energize, DV and
PM energize for a
max. of 5 min. or until
the FS opens.
2. Water Tank Drain
To 1. 1-Minute Fill Cycle
Icemaker starts at
"1. 1-Minute Fill Cycle."
4. Ice Level Lowered
BC closed
(BC actuator paddle disengaged)
Red "POWER OK" LED on solid
Minimum off time:
90-sec. minimum
90-sec. off timer terrminates
before the appliance can
restart.
3. Icemaker Off
BC closed
BC closed
Red "POWER OK" LED flashing
Red "POWER OK"
All components de-energized
LED flashing.
DV-energized after 2 sec.
FS opens or
PM-energized after 2 sec.
5-min. timer terminates
DV de-energizes
PM de-energizes
Shutdown Delay:
• Fill Cycle–15 sec. after activation.
• Harvest Cycle–15 sec. after the next
freeze cycle starts.
• 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
BC open
(BC actuator paddle engaged)
Red "POWER OK" LED flashing
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
unplug the appliance.
• 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 S1 dip switches 3, 4, 7, 8, 9, & 10
and S2 dip switches 1 through 6 are in the factory default position. S1 dip switch
1, 2, 5, and 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.
1) Remove the louver. Move the control switch to the "OFF" position, then unplug the
appliance from the electrical outlet. Clear any ice from BC.
2) Check that the 5A fuse is good.
15
1. Sequence and Component Diagnosis
3) Power On: Plug the appliance into the electrical outlet. Move the control switch to the
"ICE" position. A 5‑sec. delay occurs. CB red "POWER OK" LED turns on.
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 red "POWER OK" LED is on. If CB red "POWER OK" LED is flashing
(indicating a full bin), check BC. Move ice away from BC actuator paddle. If CB
red "POWER OK" LED continues to flash, see "II.D.1. Bin Control Check."
a) Power On Diagnosis: If CB red "POWER OK" LED is off, confirm 5A fuse is good.
Check for 115VAC at control switch #5 (GY) to neutral (W) then at control switch
#4 (P) to neutral (W). If 115VAC is present on #5 (GY) and not on #4 (P), replace
control switch. If 115VAC is present on control switch #4 (P), check for 115VAC at
HPS (P) (KM-161 Models) to neutral (W) then HPS (BR) to neutral (W). If 115VAC is
present at HPS (P) and not at HPS (BR), HPS is open. See HPS Diagnosis below.
If 115VAC is present at HPS (BR), check for 10.5VAC at CB K7 #1 red wire to CB K7
#2 red wire. If 10.5VAC is not present, check CT continuity. If open, replace CT.
b) HPS Diagnosis (KM-161B_J): Check that the condenser coil is not clogged or
restricted. Let refrigeration circuit pressures equalize. If HPS does not reset and
pressures are equalized, replace HPS. 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, strainer, and drier.
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 2" (5 cm) clearance on the right side and 5/8" (15 mm) clearance at the 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.
4) 1-Min. Fill Cycle – LED 8 is on. WV energizes. After 1 min., CB checks for a closed
FS. If FS is closed, the harvest cycle begins. If harvest cycle begins (Comp, HGV,
energized), continue to step 5a. If FS is open, WV remains energized until 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 K5 #4 (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 5, 6, and 8 are on. WV continues. Comp and HGV
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 (S1 dip switch 1 & 2
and S2 dip switch 4). WV is energized during harvest for a maximum of 6 min. or the
length of harvest minus HPT setting (S1 dip switch 7 & 8), whichever is shorter.
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 K3 #2 (V) to neutral (W). If 115VAC is not
present, check for 115VAC at CB K3 #1 (P) to neutral (W). If 115VAC is present at
CB K3 #1 (P) and not at CB K3 #2 (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 external overload, Comp start
capacitor (if applicable), 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 K5 #2 (P) to neutral (W).
If 115VAC is not present and LED 6 is on, replace CB. If 115VAC is present, check for
115VAC at HGV coil and check HGV coil continuity. Replace as needed.
c) WRV Diagnosis: Confirm WRV is not leaking by. If WRV is leaking by, confirm
HGV is open. Next, check for proper refrigerant pressures. If refrigerant pressures
are correct, adjust or replace WRV. See "IV.C. Water Regulating Valve Adjustment
(water‑cooled models)."
5b) Harvest Pump Time (Harvest Assist) – LEDs 5, 6, and 7 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 (S1 dip switch 1 & 2 and S2 dip switch 4).
When WV de-energizes, LED 8 turns off and LED 7 turns on. PM energizes. Comp and
HGV continue.
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." If the thermistor reading is in proper range, dip switch 7 is on, and PM does not
energize before harvest terminates, replace CB. If WV continues, check for 115VAC at
CB K5 #4 (O). If 115VAC is present, and LED 8 is off, replace CB. If LED 7 is on and PM
is not energized, check for 115VAC at CB K5 #3 (DBU) to neutral (W). If 115VAC is not
present, replace CB. If 115VAC is present and PM is not energized, check PM capacitor
and motor winding continuity.
5c) Initial Harvest Cycle Termination Diagnosis: 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 (S1 dip switch 1 & 2 and S2 dip switch 4). Check discharge line
temperature. For a thermistor check, see "II.F. Thermistor Check." 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 based on
S2 dip switch 4. Maximum harvest time allowed is 20 min.
NOTICE! S1 dip switch 7 must remain on. Otherwise, PM will not energize during
the last seconds of harvest.
17
6) Freeze Cycle – LED 5 and 7 is on. Comp and PM continue. FM energizes. HGV
de‑energizes. Appliance is held in freeze by a temperature/time short cycle protection
cycle. Thermistor reaches 36°F (2°C), then the 5-min. short cycle protection timer starts.
After the 5-min. short cycle protection timer terminates and FS opens, freeze cycle
terminates.
Slush Control: When slush control is enabled (S2 dip switch 6 "ON"), PM de-energizes
when thermistor reaches 50°F (10°C) (3.9kΩ) for 10 sec. then, energizes for 50 sec.
repeatedly. When thermistor reaches 34°F (1°C) (5.9kΩ) PM de-energizes for 10 sec.,
energizes for 50 sec., de-energizes for 10 sec., again, then energizes the remainder of
the freeze cycle.
a) Freeze Cycle Diagnosis: Confirm Comp and PM continue. Confirm that FM
energizes. Confirm WRV opens (water‑cooled models). Next, confirm HGV deenergizes. 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
energizes, TXV operates correctly, WRV opens, Comp is efficient, and refrigerant
charge is correct. See "VIII.A. Specification and Performance Data Sheets."
b) Comp Diagnosis: If Comp de-energizes once freeze begins, check that appliance
has not shut off on HPS (CB "POWER OK" LED off). If so, check "3)b) HPS
Diagnosis" above. If CB "POWER OK" LED is on, check for 115VAC at CB K3 #2
(V) to neutral (W). If 115VAC is not present and LED 5 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 capacitor. 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."
c) WV and HGV Diagnosis: If WV is energized, check for 115VAC at CB K5 #4 (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 K5 #2 (P) to neutral (W). If 115VAC
is present and LED 6 is off, 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, check for 115VAC at CB K5 #3 (DBU) to neutral
(W). If 115VAC is not present, replace CB. If 115VAC is present and PM is
de-energized, check PM capacitor and motor winding continuity.
e) FM Diagnosis: If FM does not energize, check for 115VAC at CB K5 #1 (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.
f) Refrigerant Pressures and TXV (KM-161B_J) Diagnosis: If evaporator is still not
cooling, check refrigerant pressures. See "VIII.A. Specification and Performance
Data Sheets." Next, 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.
18
g) WRV (KM-161B_J) 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 thermistor has reached 36°F (2°C) and the
5 min. short cycle protection timer has terminated, disconnect the 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."
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 4, 5, 6, and 7 are on (10/20 second pump-out). Timing of
the first pump-out is determined by S1 dip switches 5 and 6. See the table below.
Control Board Settings
S1 Dip Switch Setting
Pump-Out Frequency
Control Board
OFF
Every cycle
After 2nd freeze cycle
ON
Every 10 cycles
After 11th freeze cycle
No. 5
No. 6
OFF
ON
Comp continues, HGV energizes. FM de‑energizes. PM stops for 2 sec., then restarts
for 10/20 sec. depending on pump‑out timer (S1 dip switch 3 & 4) setting. When the
pump‑out timer terminates, pump‑out is complete. The pump-out frequency control
(S1 dip switch 5 and 6) 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 10 cycles or
every cycle. For details, see "III.C.4. Pump‑Out Frequency Control (S1 dip switch 5)."
19
Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after
thermistor reaches 36°F (2°C) and the 5 min. short cycle protection timer has
terminated, disconnect the FS connector. Check that CB LEDs 4, 5, 6, and 7 are on, PM
stops, then restarts, DV energizes, and water is flowing down the drain through DV. If not,
continue to steps below.
a) CB Diagnosis: Confirm FM de-energizes. If FM is energized with LEDs 4, 5, 6, and
7 on, replace CB. If PM does not stop and restart and DV does not energize, check
that CB LEDs 4, 5, 6, and 7 are on. If not, replace CB. If LEDs 4, 5, 6, and 7 are
on and PM is not energized, check for 115VAC at CB K5 #3 (DBU) to neutral (W).
If 115VAC is not present, replace CB. If 115VAC is present at CB K5 #3 (DBU) and
PM is not energized, continue to "b) PM Diagnosis:" below. If PM is energized and
DV is not energized, check for 115VAC at CB K5 #6 (GY) to neutral (W). If LED 4 is
on and 115VAC is not present at CB K5 #6 (GY), replace CB.
b) PM Diagnosis: Confirm water is flowing down DV. If not check for 115VAC CB K5 #3
(DBU) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present and
PM is de-energized, check PM capacitor, motor winding, wiring connections, and
impeller for binding.
c) DV Diagnosis: Confirm water is flowing down DV. If not check for 115VAC at CB K5
#6 (GY) to neutral (W). If 115VAC is not present, see "b) CB Diagnosis:" above.
If 115VAC is present at CB K5 #6 (GY) 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.
2. Shutdown Diagnosis
1) See "II.D.1. Bin Control Check."
Legend: BC–bin control; CB–control board; Comp–compressor; CR–compressor relay;
DV–drain valve; FM–fan motor; FS–float switch; HGV–hot gas valve;
HPS–high-pressure switch; PM–pump motor; TXV–thermostatic expansion valve;
WRV–water regulating Valve; WV–inlet water valve
20
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 S1 dip switch 3, 4, 7, 8, 9, 10 and S2 dip
switch 1 through 6 are in the factory default position. S1 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 CB "POWER OK" LED is on,
control voltage is good, continue to step 3. If CB "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, check CT primary circuit. Check
for 115VAC at CB K3 connector pin #1 (P) to neutral (W) for 115VAC. Always choose a
white (W) neutral wire to establish a good neutral connection when checking voltages.
For additional checks, see "II.H.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 5, 6, 8, 9, 4 and 7. Components (e.g., compressor) cycle
during the test.
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) With the icemaker in the cycle to be tested, check output voltage from the corresponding
pin on CB connectors 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
21
D. Bin Control Check
1. Bin Control Check
This appliance uses a mechanical bin control to control the ice level in the storage bin.
No adjustment is required.
To check BC, follow the steps below.
1) Remove the louver, move the control switch to the "OFF" position, then unplug the
icemaker from the electrical outlet.
2) Clear any ice away from BC.
3) Remove the control box, then disconnect CB K1 connector from CB.
4) Check for continuity across BC leads. When the actuator paddle is not engaged,
BC switch is closed. If open, check that the actuator paddle is not sticking. Clean if
necessary. See "II.D.2. Bin Control Cleaning." If BC switch still reads open, replace BC.
5) Reach under the evaporator and water tank and press and hold the actuator paddle;
check for continuity across the wires of the BC connector. When the actuator paddle is
engaged, BC switch is open. If closed, check that the actuator paddle is not restricted.
Clean if necessary. See "II.D.2. Bin Control Cleaning." If BC switch still reads closed,
replace BC.
6) Reconnect CB K1 connector to CB. Next, move the control switch to the "ICE" position.
7) Plug the icemaker into the electrical outlet.
8) Allow the icemaker to cycle into the freeze cycle. Once in the freeze cycle, press and
hold the actuator. View CB LEDs, the CB "POWER OK" LED should start flashing and
the icemaker should shut down according to the chart below. If not, check that the
BC/CB connector is securely reconnected. If so, replace CB.
Cycle at Bin
Shutdown
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.
9) Replace the control box and louver in their correct position.
Legend: BC–bin control; CB–control board
22
2. Bin Control Cleaning
Scale may build up on BC. Scale can cause the actuator paddle and magnet to stick.
In this case, BC 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) ­Remove the louver, move the control switch to the "OFF" position, then unplug the
icemaker from the electrical outlet.
2) Clear any ice away from BC.
3) Disconnect the silicone hose and overflow pipe. Allow the water tank to drain completely.
Next, remove the water tank by pressing down the snaps on the bracket (L) and (R),
pulling the water tank towards you slightly, and pushing it down. See Fig. 1.
Water Tank Tab
Overflow Pipe
Water Tank
Silicone Hose
Fig. 1
4) Hold both sides of the mechanical bin control, then pull forward and remove. See Fig. 2.
Actuator Paddle
Actuator Paddle
Bin Control Assembly
Fig. 2
23
Bin Control Assembly
5) Remove the actuator paddle from the switch mount.
6) Wipe down the switch mount and actuator paddle with 1 part of Hoshizaki "Scale Away"
and 25 Parts warm water. Rinse the switch mount and actuator paddle thoroughly with
clean water. See Fig. 3.
Proximity Switch
Actuator Paddle
Bin Control Assembly
Fig. 3
7) Replace the actuator paddle back on the switch mount.
8) Replace and secure the bin control assembly back in its correct position.
9) Replace and secure the water tank back in its correct position, then replace the overflow
pipe and silicone hose back in their correct positions.
10) Move the control switch to the "ICE" position.
11) Plug the icemaker back into the electrical outlet to start the automatic icemaking
process.
12) Replace the louver back in its correct position.
Legend: BC–bin control
24
E. 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 louver, move the control switch to the "OFF" position, then unplug the
icemaker from the electrical outlet.
2) Disconnect the silicone hose to drain the water, then after all the water has drained
reconnect the silicone hose back in its correct position. See Fig. 4.
Overflow Pipe
Water Tank
Silicone Hose
Fig. 4
3) Remove the control box, then disconnect CB K1 connector from CB.
4) Check for continuity across FS leads. With the water tank empty, FS should be open.
If open, continue to step 5. If closed, follow the steps in "II.E.2. Float Switch Cleaning."
After cleaning FS, check it again. Replace if necessary.
5) Reconnect CB K1 connector to CB, then replace the control box in its correct position.
6) Plug the icemaker back into the electrical outlet, then move the control switch to the
"ICE" position. 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 7.
7) Move the control switch to the "OFF" position, then unplug the icemaker from the
electrical outlet.
8) Remove the control box, then disconnect CB K1 connector CB.
9) 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.F.2. Float Switch Cleaning." After cleaning FS, check it
again. Replace if necessary.
10) Reconnect CB K1 connector to CB, then replace the control box in its correct position.
11) Move the control switch to the "ICE" position, then plug the icemaker back into the
electrical outlet to start the automatic icemaking process.
12) Replace the louver in its correct position.
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 louver, move the control switch to the "OFF" position, then unplug the
icemaker from the electrical outlet.
2) Disconnect the silicone hose to drain the water, then after all the water has drained
reconnect the silicone hose back in its correct position. See Fig. 4.
3) Remove the top and upper rear panels.
4) Disconnect the FS/CB 2-pin connector (1 black (BK) wire and 1 red (R) wire coming
from FS and 2 red (R) wires coming from CB K1 connector pins 1 and 3).
KM-81BAJ, KM-116BAJ
5) Remove the water tank. Next, remove the screw securing the FS, then remove the FS.
See Fig. 5.
KM-161BAJ, KM-161BWJ
5) Locate the FS behind the pump motor. Next, as shown in Fig. 6 pinch the FS bracket
where indicated (1) and pull it forward diagonally (2) to unhook the FS, then remove the
screw securing the FS to the bracket.
Float Switch
Bracket
Float Switch
Mounting Screw
Float Switch
Float Switch
Fig. 6
Fig. 5
6) Remove the retainer clip from FS shaft, then remove the float. Be careful not to damage
or lose the retaining clip when removing it. See Fig. 7.
7) Wipe down FS housing, shaft, float, and retainer clip with a
mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm
water. Rinse the parts thoroughly with clean water.
8) Reassemble FS assembly, then replace and secure the
removed parts in the reverse order of the removal procedure.
9) Replace the upper rear and top panels.
Float Switch
Housing
10) Plug the icemaker into the electrical outlet.
Float Switch
Shaft
11) Move the control switch to the "ICE"
position to start the automatic icemaking
process.
Float Switch
Retainer Clip
12) Replace the louver in its correct position.
Fig. 7
Legend: CB–control board; FS–float switch
26
Float Switch
Float
F. Thermistor Check
To check thermistor resistance, follow the steps below.
1) Unplug the icemaker from the electrical outlet.
2) Remove the louver, then move the control switch to the "OFF" position.
3) Remove the top panel.
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) From the compressor area, locate the thermistor/CB connector protective plastic bundle.
Open the protective plastic bundle and remove the thermistor/CB connector from the
protective plastic bundle.
7) Disconnect the thermistor connector from CB 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.
8) Replace the thermistor in its correct position. See "IV.B. Component Service
Information."
9) Reconnect the thermistor connector to CB connector and re-secure in the protective
plastic cover.
10) Replace the top panel in its correct position.
11) Plug the icemaker into the electrical outlet, then move the control switch to the "ICE"
position to start the automatic icemaking process.
12) Replace the louver in its correct position.
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
G. Switch
The control switch has three positions, "OFF" for power off, "ICE" for icemaking, and
"WASH" to energize the water pump when cleaning and sanitizing. WARNING! Moving
control switch to "OFF" position does not de-energize all components.
27
H. Diagnostic Tables
1. No Ice Production
No Ice Production - Possible Cause
1. Power Supply
a) Off, blown fuse, or tripped breaker.
b) Unplugged or loose connection.
c) Not within specifications.
2. Fuse (Control Box)
a) Blown.
3. Control Switch
a) In "OFF" or "SERVICE" position.
b) Bad contacts.
4. High-Pressure Switch
(KM-161 B_J Models)
a) Dirty condenser.
b) Fan motor not operating.
c) Refrigerant overcharged.
d) Bad contacts.
e) Refrigerant lines or components plugged.
f) HGV defective.
5. Control Transformer
(115VAC/10.5VAC)
a) Coil winding open or shorted.
6. Control Board
See "II.C. Control Board Check"
a) In alarm.
b) CB "POWER OK" LED flashing (bin full).
c) Defective.
7. Bin Control
See "II.D. Bin Control Check"
a) Tripped with bin filled with ice.
b) Actuator does not move freely.
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 defective.
c) External protector open.
d) Start relay contacts bad or coil winding open.
e) Compressor defective.
12. Hot Gas Valve
a) Closed in harvest cycle.
b) Open in freeze cycle.
13. Thermistor
See "II.F. Thermistor Check"
a) Loose, disconnected, or defective.
14. Pump Motor
a) Motor winding open.
b) Bearing worn out or locked rotor.
c) Defective capacitor.
d) Mechanical seal worn out.
28
No Ice Production - Possible Cause
15. Thermostatic Expansion Valve
(KM-161 B_J Models)
a) Bulb loose.
16. Fan Motor
a) Motor winding open.
b) Operating erratically.
b) Bearing worn out or locked rotor.
c) Defective capacitor.
17. 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 "II.I. Freeze Up Check List," 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 (S1 dip switch 1 & 2) set too short.
b) Defective.
b) Harvest pump timer (S1 dip switch 7) not in factory default position.
c) Defective.
9. Bin Control
See "II.D. Bin Control Check"
a) Actuator does not move freely.
10. Thermistor
See "II.F. Thermistor Check"
a) Loose, disconnected, or defective.
11. Thermostatic Expansion Valve
(KM-161 B_J Models)
a) Defective.
12. Hot Gas Valve
a) Closed or restricted.
29
Freeze-Up - Possible Cause
Freeze Cycle
1. Evaporator
a) Scaled up.
b) Damaged.
2. Spray Tubes and/or Spray
Guides
a) Dirty.
3. Refrigerant Charge
a) Low.
4. Control Board
See "II.C. Control Board Check"
a) Freeze timer (S1 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) Out of position.
b) Defective.
b) Defective.
b) Impeller damaged.
8. Thermostatic Expansion Valve
(KM-161 B_J Models)
a) Bulb loose or defective.
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.
8. Inlet Water Valve
a) Screen or orifice clogged.
9. Compressor
a) Inefficient or off.
10. Thermostatic Expansion Valve
(KM-161 B_J Models)
b) Defective.
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.
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) Float sticking.
c) Defective switch.
b) Defective.
7. Refrigerant Charge
a) Low.
8. Thermostatic Expansion Valve
(KM-161 B_J Models)
a) Bulb loose.
9. Compressor
a) Inefficient or off.
10. Pump Motor
b) Defective.
a) RPM too slow.
31
I. Freeze-Up Check List
Freeze-Up Check List
Please Complete When Diagnosing a Freeze-Up, Refrigerant Leak, or Low Charge
Technical Support Fax #: 770-487-3360
Make Copies And Use As Needed
Model #___________________________ Serial # _________________________Install Date______________Fail Date___________
List model and manufacture of bin or dispenser__________________________.
Date appliance was last cleaned:__________.
Appliance Operation
Freeze-Up Defrost
YES NO
[ ]
[ ]
1) After defrosting, was the appliance leak
checked?
[ ]
[ ]
2) Were any leaks found?
If so where?_____________________.
[ ]
[ ]
3) Was any refrigerant added to the unit?
If so, how much?_________________.
Set Up
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
Fill
YES NO
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
replaced?__________________________.
[ ]
[ ]
system?__________________.
9) Ambient temperature at appliance?
______________.
At remote condenser (if applicable)?________.
[ ]
[ ]
[ ]
[ ]
4) Is the appliance stand alone?
5) Is water line independent?
6) Is water line correct size? If not________”.
3/8" Nominal ID Copper Water Tubing or
Equivalent.
7) What is water pressure?___________.
Water Temperature_________.
[ ]
If yes please list the following:
Filter brand___________________.
Model________________.
cycle___________.
Appliance Status
[ ]
11) List the S1 (1-10) and S2 (1-5) DIP switch
settings.
S1: 1___2___3___4___5___6___7___8___9___10____
S2: 1_____2_____3_____4_____5______6______
[ ]
[ ] 12) Is DIP switch number 7 ON (harvest pump
time (harvest assist) all models and freeze-time
correction models with control board
2A7664-02?
[ ]
[ ] 13) Is the cube guide positioned correctly?
[ ]
[ ] 14) Are the evaporator separators positioned
properly?
[ ]
[ ] 15) Is the thermistor properly mounted, tight, and
insulated?
[ ]
[ ] 16) Is the TXV bulb properly mounted, tight, and
insulated?
17) Are the splash guards in place?
18) Does the water tank fill and overflow?
60-90 sec. Note: Larger models may take up
to 120 seconds to overflow when empty.
19) If NO in step 17, is
Harvest
20) Is the hot gas valve opening?
21) Is harvest pump time (harvest assist) utilized
(S1 dip switch 7)?
22) Is hot gas valve opening in harvest?
23) Does water valve close completely when
deenergized?
24) What was length of harvest?___________.
Freeze
25) Is pump motor energized in freeze cycle except
during 10-sec. anti-slush. If activated (S2 dip
switch 5 on)?
26) Water-cooled condenser outlet temperature
27) What was length of freeze?____________.
28) Is the cube size consistent from inlet to outlet of
evaporator?
29) Is ice still dropping when next freeze cycle starts?
30) What is the ice drop weight?___________.
31) What is head pressure?
Freeze_________Harvest_______.
(Freeze pressure should be taken 5 minutes into
the cycle).
32) What is suction pressure?
Freeze______Harvest_______.
(Freeze pressure should be taken 5 minutes into
the cycle).
33) When activating bin control, did appliance
of freeze cycle?
Note: Make copies of this form and use it when diagnosing a freeze up condition. Submit a completed copy of the checklist
along with the freeze-up labor claim form.
1
32
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 short out power supply to test for voltage.
• Always replace the whole control board assembly if it goes bad.
33
A. Control Board Layout
Control Board
• Relay LEDs (6)
(indicate which relays
are energized as
listed below)
• K7 Connector
Transformer
• LED 5 (X1 Relay)
Compressor (Comp)
Fan Motor-Remote
(FMR)
• LED 6 (X2 Relay)
Hot Gas Valve (HGV)
Fan Motor (FM)
(FM off when LED on)
• K3 Connector
Power Relay
• "POWER OK" LED
(Lights when power is
supplied to the board.
Flashes when bin
control is activated.)
• LED 8 (X4 Relay)
Inlet Water Valve (WV)
(WV1) on units with
2 inlet water valves
• K5 Connector
Pins
#1 Fan Motor (FM)
#2 Hot Gas Valve
#3 Pump Motor
#4 Inlet Water Valve
#5 Open
#6 Drain Valve
• LED 9 (X5 Relay)
Inlet Water Valve 2
(WV2) on units with
2 inlet water valves
• LED 4 (X6 Relay)
Drain Valve (DV)
• LED 7 (X3 Relay)
Pump Motor (PM)
• K6 Connector
Open
• Alarm Buzzer
• "OUTPUT TEST" Button
(used to test relays on
control board)
• K1 Connector
Pins
#1, 3 Float Switch
#2 Open
#4, 5 Bin Control
#6, 7 Thermistor
#8, 9 Open
• "ALARM RESET" Button
• S1 Dip Switch
• S2 Dip Switch
Control Board
Part Number P01771-02
34
B. LED Lights and Audible Alarm Safeties
Beep occurs and red CB "POWER OK" LED turns on when control switch is moved to
"ICE" position.
Sequence
Green LEDs 4 through 8 turn on and sequence from initial startup as listed in the
table below. Order of green LEDs from the outer edge of control board is 5, 6, 8, 9, 4,
7.
Sequence Step
LED
Energized
Components
Time LEDs are On
Min.
Max.
1-Minute Fill Cycle
8
WV
Harvest Cycle
5, 6, 8
Comp, FM, HGV, WV
2 minutes 20 minutes
Last 0, 10, 30, or 50 seconds (adjustable by dip switch) of harvest, WV de-energizes and PM energizes
(LEDs 5, 6, and 7 are on)
Freeze Cycle
5, 7
Comp, FM, PM
5 minutes freeze timer
setting
Pump-Out Cycle
5, 6, 4,7 Comp, HGV, PM, DV
10 seconds 20 seconds
Alarms
Type
1
Beep
2
Beep
Alarm
Notes
High Evaporator Temp.
Check for harvest problem (stuck HGV or relay), hot water
(temperature > 127°F) (53°C) entering unit, or shorted thermistor.
Harvest Backup Timer
Check thermistor (open), HGV not opening, TXV leaking
(harvest > 20 min. for two
by, low charge, inefficient Comp, or WRV leaking by.
cycles in a row)
3
Freeze Timer
Check FS stuck closed (up), WV leaking by, HGV leaking
Beep
(freeze > freeze timer setting by, PM not pumping, TXV defective, low charge, or
for two cycles in a row)
inefficient Comp.
To reset above safeties, press "ALARM RESET" button with power supply on.
6
Low Voltage
Red LED turns off if voltage protection operates.
(92Vac±5% or less)
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; FS–float switch; HGV–hot gas
valve; PM–pump motor; TXV–thermostatic expansion valve; WRV–water regulating
valve; WV–inlet water valve
35
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:
S1 Dip Switch No.
1
2
3
4
5
6
7
ON
8
9
10
KM-81BAJ
OFF OFF ON OFF ON
ON
ON OFF ON
KM-116BAJ
ON OFF ON OFF ON
ON OFF ON OFF ON
KM-161BAJ
OFF OFF ON
ON
ON
ON
ON
ON OFF ON
KM-161BWJ
OFF OFF ON
ON
ON
ON
ON
ON
ON OFF
S2 Dip Switch (Do Not Adjust)
Dip Switch No.
KM-81BAJ
KM-116BAJ
KM-161BAJ
KM-161BWJ
1
2
3
4
5
6
OFF OFF OFF OFF OFF ON
Do not adjust the S2 dip switch. These must be left in the factory default position, or the
appliance will not operate properly.
1 2 3 4 5 6 7 8 9 10
ON
S1 Dip Switch
Freeze Timer (9 & 10)
Harvest Pump Time Duration (Harvest Assist) (7 & 8)
Pump-Out Frequency Control (5 & 6)
Pump-Out Time (3 & 4)
Harvest Time (1 & 2)
S2 Dip Switch (Do Not Adjust)
1 2 3 4 5 6
ON
Slush Control (6)
Overfreeze Detection Control (5)
Harvest Completion Detection Control (4)
Refill Counter (3)
Harvest Promotion Control (2)
Pump-Out/Drain Selector (1)
36
2. Harvest Time (S1 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. Note that the pump-out timer (S1 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 (S1 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.
S1 Dip Switch Setting
No. 1
No. 2
Time
(sec.)
OFF
OFF
60
ON
OFF
90
OFF
ON
120
ON
ON
180
3. Pump-Out Time/Harvest Time During Pump-Out (S1 dip switch 3 & 4)
When a pump-out is called for, the pump motor stops for 2 seconds, then the pump
motor and drain valve 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. The pump-out timer control can be set to pump-out for 10 or 20 seconds.
During pump-out cycles minimum harvest time is based on times given in the
table below.
S1 Dip Switch Setting
Time (sec.)
No. 3
No. 4
T1
T2
OFF
OFF
10
120
ON
OFF
20
160
OFF
ON
20
120
ON
ON
20
180
T1: Time to drain the water tank
T2: Harvest timer at pump out
37
4. Pump-Out Frequency Control (S1 dip switch 5 & 6)
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 S1 dip switch 5 & 6. See the table below.
S1 Dip Switch Setting
Pump-Out Frequency
No. 5
No. 6
OFF
OFF
Every cycle
ON
OFF
Every 2 cycles
OFF
ON
Every 5 cycles
ON
ON
Every 10 cycles
5. Harvest Pump Time Duration (Harvest Assist) (S1 dip switch 7 & 8)
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 timer allows the water valve to close and the pump motor to circulate
water in the tank during the final part of harvest. The water valve is open during harvest
for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds
(determined by the harvest pump timer setting), whichever is shorter. When the water
valve closes, the pump motor energizes and runs for the time determined by the harvest
pump timer setting. The harvest pump timer is factory-adjusted, and no adjustment is
required.
S1 Dip Switch Setting
Harvest Pump
Time Duration
(Harvest Assist)
No. 7
No. 8
OFF
OFF
0 sec.
ON
OFF
10 sec.
OFF
ON
30 sec.
ON
ON
50 sec.
38
6. Freeze Timer (S1 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.H.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.
S1 Dip Switch Setting
No. 9
No. 10
Time
(min.)
OFF
OFF
60
OFF
ON
50
ON
OFF
70
ON
ON
100
7. Pump-Out/Drain Selector (S2 dip switch 1)
The pump-out/drain selector setting determines whether the pump motor energizes
(pump-out) or stays off (drain) after a 2-second delay at the beginning of the pump-out
cycle or at shutdown. Regardless of the pump-out/drain selector setting, the drain valve
energizes after a 2-second delay at the beginning of the pump-out cycle or at shutdown.
When the pump-out/drain selector is set to pump-out, the pump motor takes water from
the tank and forces it through the drain valve and down the drain. When the pump-out/
drain selector is set to drain, water drains by gravity through the drain valve.
S2 Dip Switch Setting Pump Operation
No. 1
Setting
OFF
Drain
ON
Pump-Out
8. Harvest Promotion Control (S2 dip switch 2)
NOTICE
Do not adjust. These must be left in the factory default position or the icemaker will
not operate correctly.
When activated, this control promotes harvest of ice on the evaporator that is hard to
remove. If the harvest cycle exceeds 6 minutes, the pump motor starts to operate for a
maximum of 3 minutes.
S2 Dip Switch Setting
No. 2
Harvest Promotion
Control
OFF
Enabled
ON
Disabled
39
9. Minimum Harvest Time (S2 dip switch 3)
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside the factory
default setting may result in damage to the appliance.
Do not adjust. This must be left in the factory default position or the unit will not operate
properly. The KM-81BAJ, KM-116BAJ, and KM-161BAJ/BWJ do not refill.
10. Harvest Completion Detection Control (S2 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.
It is deactivated on the KM-81BAJ, KM-116BAJ, and KM-161BAJ/BWJ.
When activated, this control determines whether ice remains on the evaporator at the
end of a harvest cycle and at the beginning of a freeze cycle. If ice drops and activates
the bin control switch in the last 10 seconds of a harvest cycle, the control determines
that ice still remains on the evaporator and extends the harvest cycle for 30 seconds.
If the bin control switch is activated at the beginning of a freeze cycle, the control
determines that ice still remains on the evaporator and starts a harvest cycle after the
minimum freeze cycle time has passed.
S2 Dip Switch Setting
No. 4
Slush
Control
OFF
Disabled
ON
Enabled
40
11. Overfreeze Detection Control (S2 dip switch 5)
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside the factory
default setting may result in damage to the appliance.
Do not adjust. This must be left in the factory default position or the unit will not operate
properly. It is deactivated on the KM-81BAJ, KM-116BAJ, and KM-161BAJ/BWJ.
When activated, the thermistor detects the temperature of the evaporator outlet to find
overfreeze in a harvest cycle and at the beginning of a freeze cycle. If the difference
between the maximum temperature after the harvest pump timer starts counting and the
temperature at the end of a harvest cycle is 7.2°F (4°C) or more and if the temperature
at the end of a harvest cycle is 48°F (9°C) or less, the harvest cycle is extended for 30
seconds. If the difference between the temperature at the beginning of a freeze cycle
and the minimum temperature after 30 seconds in the freeze cycle is 2.5kΩ or more
and less than 3.5kΩ, the next harvest cycle is extended for 30 seconds. If the above
conditions occur in succession, the number of occurrence times 30 seconds will be
added to the harvest cycle time. If the above temperature difference is 3.5kΩ or more, the
freeze cycle ends after the minimum freeze cycle time and a harvest cycle starts.
If the evaporator outlet temperature is more than 3.5°C but not more than 5°C at the end
of harvest cycle, the harvest cycle is extended for 50 seconds before moving on to the
freeze cycle. If the evaporator outlet temperature is 3.5°C or less, another harvest cycle
starts. The harvest cycle does not repeat more than three times. The freeze cycle starts
even if the evaporator outlet temperature is 3.5°C or less at the end of the third harvest
cycle.
S2 Dip Switch Setting
No. 5
Overfreeze Detection
Control
OFF
Disabled
ON
Enabled
41
12. Slush Control (S2 dip switch 6)
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside the factory
default setting may result in damage to the appliance.
This dip switch setting provides slush control during the freeze cycle.
Disabled (OFF): When the evaporator temperature reaches 41°F (5°C) the control board
reads a 4.8 kΩ signal from the thermistor and de-energizes the water pump for 10 sec.,
then energizes the water pump for the duration of freeze time.
Enabled (ON): When the evaporator temperature reaches 50°F (10°C) the control board
reads a 3.9kΩ signal from the thermistor and de-energizes the water pump for 10 sec.
and energize it for 50 secs. repeatedly. When 34°F (1°C) is reached, a 5.9 kΩ signal
causes the control board to de‑energize the pump motor for 10 secs., energize it for 50
secs., de-energize it again for 10 secs., then energize it continuously.
S2 Dip Switch Setting
No. 6
Slush
Control
OFF
Disabled
ON
Enabled
42
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
No refrigerant access valves are provided on this appliance. Using proper refrigerant
practices, utilize a temporary tap-line valve on the high side to recover the refrigerant.
Store the refrigerant in an approved container. Do not discharge the refrigerant into
the atmosphere. After recovery is complete, replace the tap-line valve with a proper,
permanent access valve.
43
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 debrazing 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 the
low-side refrigerant access valve and the field-installed high-side access valve.
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.
44
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.
45
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.
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
• Replace the strainer if applicable.
• Use copper tube of the same diameter and length when replacing valve lines.
Fan Motor
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. 8. 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.
46
Fig. 8
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 plug with
damp hands
• Before servicing: Move the control switch to the "OFF" position and unplug the
power supply cord from the electrical outlet.
• 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.
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.
Icemaker and Ice Clean and sanitize per the cleaning and sanitizing instructions provided
Storage Bin Liner in the instruction manual or maintenance label on the icemaker.
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
47
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) Remove the louver, then move the control switch to the "OFF" position. Wait 3 min.
2) Close the icemaker water supply line shut-off valve and open the icemaker water supply
line drain valve.
3) Allow the line to drain by gravity.
4) Attach a compressed air or carbon dioxide supply to the icemaker water supply line
drain valve.
5) Make sure at least 3 min. have elapsed. Move the control switch to the "ICE" position.
6) Blow the icemaker water supply line out using the compressed air or carbon dioxide
supply.
7) Close the icemaker water supply line drain valve.
2. Remove the water from the water tank:
1) Move the control switch to the "OFF" position, then unplug the appliance from the
electrical outlet.
2) Disconnect the silicone hose to drain the water. See Fig. 9.
3) After all of the water has drained, reconnect the silicone hose back in its correct
position.
4) Remove all ice from the ice storage bin. Clean the storage bin liner using a neutral
cleaner. Rinse thoroughly after cleaning.
Overflow Pipe
Water Tank
Silicone Hose
Fig. 9
48
3. On water-cooled model, remove the water from the water-cooled condenser:
1) Make sure the appliance is unplugged and the control switch is in the "OFF" position.
2) Remove the rear cover.
3) 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.
4) Open the condenser water supply line drain valve. If connected to a closed loop system,
also open the condenser return line drain valve.
5) Attach a compressed air or carbon dioxide supply to the condenser water supply line
drain valve.
6) Open the water regulating valve by using a screwdriver to pry up on the spring retainer
underneath the spring. While holding the valve open, blow out the condenser using the
compressed air or carbon dioxide supply until water stops coming out.
7) Close the drain valve(s).
8) Replace the rear cover in its correct positions.
49
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.
50
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. KM-81BAJ
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
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
115/60/1
3.5 A (5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
90/70°F
70/50°F
180 (8.45)
210 (6.30)
10 (19.5)
22 (27.4)
1.5 lbs. (0.7 kg) 80pcs.
38 LBS.
Mechanical Bin Control
R134a, 0 lb. 7.1 oz. (200g)
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
AMBIENT
TEMP. (ºF/ºC)
70/21
80/27
90/32
lbs./day kg./day
100/38
70/21
APPROXIMATE ELECTRIC
80/27
CONSUMPTION
90/32
watts
100/38
70/21
APPROXIMATE WATER
80/27
CONSUMPTION PER 24 HR.
90/32
gal./day m3/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/cm 2G
100/38
70/21
SUCTION PRESSURE
80/27
90/32
PSIG kg/cm 2G
100/38
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
50/10
78
73
71
72
22
19
18
15
102
111
114
121
23
22
22
23
51
210
203
201
223
26
28
28
28
2.1
2.1
2.1
2.1
WATER TEMP. (ºF/ºC)
70/21
90/32
71
32
67
30
36
33
60
27
61
28
32
52
24
50
23
33
52
23
49
22
233
201
246
190
180
227
270
191
18
0.07
17
0.06
0.08
0.07
14
0.05
15
0.06
0.07
10
0.04
10
0.04
0.06
10
0.04
10
0.04
29
28
30
32
35
34
33
34
2.1
2.1
2.1
2.1
2.0
2.0
2.0
2.0
114
8.0
138
9.7
7.2
7.8
131
9.2
158
11.1
8.0
144
10.1
170
12.0
8.5
150
10.6
194
13.6
1.6
22
1.6
23
1.6
1.6
21
1.5
23
1.6
1.6
20
1.4
22
1.5
1.6
20
1.4
23
1.6
1,350 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
250 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
2. KM-116BAJ
Specification Data
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
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
115/60/1
5.5 A (5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
90/70°F
70/50°F
340 (8.10)
330 (6.44)
20 (20.0)
25 (19.9)
2.2 lbs. (1 kg) 110pcs.
53 LBS.
Mechanical Bin Control
R134a, 0 lb. 7.8 oz. (220g)
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
AMBIENT
TEMP. (ºF/ºC)
70/21
80/27
90/32
lbs./day kg./day
100/38
70/21
APPROXIMATE ELECTRIC
80/27
CONSUMPTION
90/32
watts
100/38
70/21
APPROXIMATE WATER
80/27
CONSUMPTION PER 24 HR.
90/32
gal./day m3/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
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
125
119
118
114
25
24
23
21
112
125
128
131
12
14
14
15
50/10
330
332
333
340
23
24
25
27
4.2
3.8
3.7
3.0
WATER TEMP. (ºF/ºC)
70/21
90/32
118
53
105
48
57
54
108
49
95
43
53
100
46
87
40
52
97
44
75
34
333
349
337
360
340
361
345
380
23
0.09
20
0.08
0.09
0.09
22
0.08
18
0.07
0.09
20
0.08
16
0.06
0.08
19
0.07
13
0.05
25
30
27
33
30
35
31
40
3.7
3.3
3.0
2.9
2.4
2.2
2.3
2.0
128
9.0
148
10.4
7.9
8.8
150
10.5
168
11.8
9.0
168
11.8
187
13.2
9.2
173
12.1
205
14.4
0.8
14
1.0
17
1.2
1.0
17
1.2
20
1.4
1.0
19
1.3
22
1.6
1.0
20
1.4
25
1.8
2,100 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
380 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
ENG.F-011.1.0205
52
3. KM-161BAJ
Specification Data
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
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
115/60/1
7.1 A (5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
90/70°F
70/50°F
440 (8.60)
440 (6.47)
28 (23.0)
49 (30.1)
2.6 lbs. (1.2 kg) 130pcs.
78 LBS.
Mechanical Bin Control
R134a, 0 lb. 7.4 oz. (210g)
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
AMBIENT
TEMP. (ºF/ºC)
70/21
80/27
90/32
lbs./day kg./day
100/38
70/21
APPROXIMATE ELECTRIC
80/27
CONSUMPTION
90/32
watts
100/38
70/21
APPROXIMATE WATER
80/27
CONSUMPTION PER 24 HR.
90/32
gal./day m3/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
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
163
154
151
148
49
44
43
36
122
133
137
139
13
14
14
14
50/10
440
440
440
453
21
22
23
24
2.4
2.4
2.3
2.2
WATER TEMP. (ºF/ºC)
70/21
90/32
151
69
135
61
74
70
136
62
120
54
69
123
56
107
48
67
120
54
92
42
440
463
440
476
440
471
447
500
43
0.16
39
0.15
0.19
0.17
35
0.13
33
0.13
0.16
28
0.11
26
0.10
0.14
28
0.11
23
0.09
23
27
25
30
26
31
28
36
2.3
2.3
2.2
2.2
2.0
2.0
2.0
2.0
137
9.6
153
10.8
8.6
9.4
157
11.0
171
12.0
9.6
173
12.2
189
13.3
9.8
177
12.4
203
14.3
0.9
14
1.0
15
1.1
1.0
15
1.1
16
1.1
1.0
16
1.1
17
1.2
1.0
16
1.1
18
1.3
3,050 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
130 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
ENG.F-011.1.0205
53
4. KM-161BWJ
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
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
115/60/1
6.4 A (5 Min. Freeze AT 104°F / WT 80°F)
15 A
15 A
90/70°F
70/50°F
330 (6.23)
360 (5.61)
31 (24.2)
53 (35.0)
0 (0)
0 (0)
2.5 lbs. (1.1 kg) 130pcs.
78 LBS.
Mechanical Bin Control
R134a, 0 lb. 10.6 oz. (300g)
Peformance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
AMBIENT
TEMP. (ºF/ºC)
70/21
80/27
90/32
lbs./day kg./day
100/38
70/21
APPROXIMATE ELECTRIC
80/27
CONSUMPTION
90/32
watts
100/38
70/21
APPROXIMATE WATER
80/27
CONSUMPTION PER 24 HR.
90/32
gal./day m3/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
TOTAL HEAT OF REJECTION FROM CONDENSER
TOTAL HEAT OF REJECTION FROM COMPRESSOR
153
147
146
146
53
48
47
186
137
137
137
138
11
11
12
12
50/10
360
353
351
360
22
23
23
23
2.7
2.6
2.5
2.3
WATER TEMP. (ºF/ºC)
70/21
90/32
146
66
140
64
69
67
136
62
133
60
66
128
58
124
56
66
127
58
121
55
351
360
340
360
330
346
334
360
47
0.18
388
1.47
0.20
0.18
38
0.15
574
2.17
0.18
31
0.12
491
1.86
0.70
139
0.53
914
3.46
23
25
24
26
25
27
25
29
2.5
2.5
2.3
2.3
2.1
2.0
2.1
2.0
137
9.7
139
9.8
9.6
9.6
138
9.7
140
9.8
9.7
138
9.7
140
9.8
9.7
138
9.7
142
10.0
0.8
12
0.8
13
0.9
0.8
12
0.9
15
1.0
0.8
13
0.9
15
1.1
0.9
13
0.9
17
1.2
2,900 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
450 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
ENG.F-011.1.0205
54
OFF
OFF
ON
OFF
OFF
KM-116BAJ
KM-161BAJ
KM-161BWJ
ON
ON
ON
OFF
OFF
OFF
KM-81BAJ
KM-116BAJ
KM-161BAJ
KM-161BWJ
2
OFF
OFF
OFF
OFF
START CAP.
100MFD
189-227MFD
MODEL
KM-116BAJ
KM-161BWJ
3
OFF
OFF
OFF
OFF
COMPRESSOR CAPACITOR TABLE
1
OFF
SWITCH No.
KM-161BAJ
ON
ON
OFF
OFF
4
4
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
5
ON
ON
ON
ON
5
ON
ON
ON
ON
6
ON
ON
ON
ON
6
S1 DIP SWITCH SETTINGS
ON
3
S2 DIP SWITCH SETTINGS
OFF
OFF
OFF
KM-81BAJ
2
1
SWITCH No.
7
ON
ON
OFF
ON
8
9
ON
OFF
OFF
OFF
10
OFF
ON
ON
ON
55
CONDENSER FAN
MOTOR
CABINET FAN MOTOR
KM-81BAJ
KM-116BAJ
KM-161BAJ
KM-161BWJ
PTC RELAY
KM-81BAJ
COMPRESSOR
EXTERNAL
PROTECTOR
327±22 PSIG
Cut-in
284±22 PSIG
384±22
0 PSIG
412± 0 PSIG
Cut-out
22
Water-Cooled Model
* High-Pressure Switch
Air-Cooled Model
Optional Drain Pump Connector
CONTROL
SWITCH
*
FAN MOTOR
START
CAP.
(SEE
TABLE)
START RELAY
COMPRESSOR
RELAY
FUSE 5A
1. KM-81BAJ, KM-116BAJ, KM-161BAJ, KM-161BWJ
MODEL
JUMPER
KM-81BAJ and
KM-116BAJ Models
Optional Drain Pump Connector
ON
ON
ON
ON
B. Wiring Diagram
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