Hoshizaki KM-1100MAJ50 Service Manual

Hoshizaki KM-1100MAJ50 Service Manual

Service Manual Modular Crescent Cuber

Models KM-1100MAJ50

hoshizakiamerica.com

Number: 73231 Issued: 9-12-2018

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 ................................................................................................. 4

I. Construction and Water/Refrigeration Circuit Diagram ....................................................... 6 A. Construction .................................................................................................................. 6

B. Water/Refrigeration Circuit Diagram .............................................................................. 7

II. Sequence of Operation and Service Diagnosis ................................................................. 8 A. Sequence of Operation Flow Chart ............................................................................... 8

B. Service Diagnosis ....................................................................................................... 10

C. Control Board Check ................................................................................................... 17

D. Bin Control Check ....................................................................................................... 18

E. Float Switch Check and Cleaning ............................................................................... 19

F. Thermistor Check ......................................................................................................... 21 G. Control Switch ............................................................................................................. 21

H. Diagnostic Tables ........................................................................................................ 22

I. Freeze-Up Check List ................................................................................................... 26

III. Controls and Adjustments ............................................................................................... 27

A. Control Board Layout .................................................................................................. 28

B. LED Lights and Audible Alarm Safeties ....................................................................... 29

C. Settings and Adjustments ............................................................................................ 30 1. Default Dip Switch Settings .................................................................................... 30

2. Harvest Timer (S4 dip switch 1 & 2) ...................................................................... 31 3. Pump-Out Timer/Harvest Time During Pump-Out (S4 dip switch 3 & 4) ............... 31

4. Pump-Out Frequency Control (S4 dip switch 5) ..................................................... 32 5. Harvest Pump Time (Harvest Assist Duration) (S4 dip switch 6) ........................... 32

6. Harvest Pump Time (Harvest Assist) (S4 dip switch 7) ........................................ 33 7. Factory Use (S4 dip switch 8)................................................................................. 33

8. Freeze Timer (S4 dip switch 9 & 10) ...................................................................... 34 9. Float Switch Selector (S5 dip switch 1) ................................................................. 34 10. Refill Counter (S5 dip switch 2 and 3) .................................................................. 34

11. Minimum Harvest Time (S5 dip switch 4) ............................................................. 35 12. Anti-Slush (S5 dip switch 5) ................................................................................. 35

IV. Refrigeration Circuit and Component Service Information.............................................. 36 A. Refrigeration Circuit Service Information .................................................................... 36

B. Component Service Information .................................................................................. 39

V. Maintenance .................................................................................................................... 40

VI. Preparing the Appliance for Periods of Non-Use ............................................................ 41

VII. Disposal ......................................................................................................................... 43

VIII. Technical Information .................................................................................................... 44 A. Specification and Performance Data Sheets ............................................................... 44

B. Wiring Diagram ........................................................................................................... 45

3

Important Safety Information

Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property.

WARNING

Indicates a hazardous situation which could result in death or serious injury.

NOTICE

Indicates a situation which could result in damage to the appliance or property.

IMPORTANT

Indicates important information about the use and care of the appliance.

WARNING

The appliance should be destined only to the use for which it has been expressly conceived. Any other use should be considered improper and therefore dangerous. The manufacturer cannot be held responsible for injury or damage resulting from improper, incorrect, and unreasonable use. Failure to service and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.

To reduce the risk of death, electric shock, serious injury, or fire, follow basic precautions including the following:

• Only qualified service technicians should install and service this appliance.

• The appliance must be installed in accordance with applicable national, state, and local codes and regulations. • Electrical connection must be hard-wired and must meet national, state, and local electrical code requirements. Failure to meet these code requirements could result in death, electric shock, serious injury, fire, or severe damage to equipment.

• The icemaker requires an independent power supply of proper capacity. See the nameplate for electrical specifications. Failure to use an independent power supply of proper capacity can result in a tripped breaker, blown fuses, damage to existing wiring, or component failure. This could lead to heat generation or fire.

THE ICEMAKER MUST BE GROUNDED.

Failure to properly ground the icemaker could result in death or serious injury.

• Move the control switch to the "OFF" position and turn off the power supply before servicing. Lockout/Tagout to prevent the power supply from being turned back on inadvertently.

• To reduce the risk of electric shock, do not touch the control switch with damp hands.

• Do not make any alterations to the unit. Alterations could result in electric shock, injury, fire, or damage to the unit.

• The appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

4

WARNING, continued

• Children should be properly supervised around this appliance.

• Do not climb, stand, or hang on the appliance or allow children or animals to do so. Serious injury could occur or the appliance could be damaged.

• Do not use combustible spray or place volatile or flammable substances near the appliance. They might catch fire.

• Keep the area around the appliance clean. Dirt, dust, or insects in the appliance could cause harm to individuals or damage to the appliance.

NOTICE

• Follow the instructions in this manual carefully to reduce the risk of costly water damage.

• In areas where water damage is a concern, install in a contained area with a floor drain. • Install the appliance in a location that stays above freezing. Normal operating ambient temperature must be within 45°F to 100°F (7°C to 38°C).

• Do not leave the icemaker on during extended periods of non-use, extended absences, or in sub-freezing temperatures. To properly prepare the icemaker for these occasions, follow the instructions in "VI. Preparing the Appliance for Periods of Non-Use." • Do not place objects on top of the appliance.

• The dispenser unit/ice storage bin is for ice use only. Do not store anything else in the dispenser unit/ice storage bin.

5

I. Construction and Water/Refrigeration Circuit Diagram A. Construction

1. Air-Cooled Models (MAJ)

Spray Tubes Inlet Water Valve Cleaning Valve Hot Gas Valve Water Supply Inlet Thermostatic Expansion Valve Control Switch Condenser Fan Motor Float Switch Water Pump Control Box Compressor Liquid Line Valve Drier High-Pressure Switch 6

B. Water/Refrigeration Circuit Diagram

1. Air-Cooled Models (MAJ)

Spray Tubes Condenser Water Supply Cleaning Valve Inlet Water Valve Drier Evaporator Fan Liquid Line Valve Thermistor Heat Exchanger High-Pressure Switch Suction Line Float Switch Water Tank Water Pump Freeze Pump Out Drain Compressor Discharge Line Thermostatic Expansion Valve Strainer Hot Gas Valve Refrigeration Circuit Water Circuit Check Valve 7

II. Sequence of Operation and Service Diagnosis A. Sequence of Operation Flow Chart

1. Operation Flow Chart

8

2. Shutdown Flow Chart

Shutdown Flow Chart

Shutdown and Restart

BC Operation

1. Bin Full

Within 10 sec.

after ice contacts BC bulb, icemaker shuts down.

2. Icemaker Off

All components de-energized.

3. Ice Level Lowered

No ice touching BC bulb. Icemaker starts at "1. 1-Minute Fill Cycle." To

1. 1-Minute Fill Cycle

Ice contacts BC bulb

BC

open All components de-energized

BC

closed

Legend: BC–

bin control 9

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 switches and S5 dip switches 1 through 5 are in the factory default position. S4 dip switch 1, 2, 3, 4, and 5 are cleaning adjustments and the settings are flexible. For factory default settings, see "III.C.1. Default Dip Switch Settings." Note: • On 208-230/60/1 models with main transformer and 208-230/60/3 models, the appliance neutral (W) is provided through the main transformer. To confirm a good neutral, check for 60VAC from white (W) neutral to ground (GND). If 60VAC is present, neutral is good. If 60VAC is not present, check 208-230VAC main power supply to main transformer. If 208-230VAC is present, check main transformer continuity.

• 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.

1) Turn off the power supply, then access the control box. Move the control switch to the "OFF" position. Clear any ice from BC bulb. 2) Check that BC is closed and the 115VAC 10A fuse is good.

10

1. Sequence and Component 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 CB green "BC CLOSED" LED turn on. If CB yellow "BC OPEN" LED is on (indicating a full bin), check CB K4 red jumper. Move ice away from BC bulb.

Note: • CB red "POWER OK" LED remains on unless the 10.5VAC power supply is interrupted (K2 connector).

• Check CB using the steps in "II.C. Control Board Check." • Confirm CB green "BC CLOSED" LED is on. If CB yellow "BC OPEN" LED is on, confirm CB K4 jumper is in place. Otherwise, CB yellow "BC OPEN" LED is on and appliance will not start.

a)

Power On Diagnosis:

If CB red "POWER OK" LED is off, confirm 10A fuse is good. Check for 115VAC at control switch #1 (LBU) to neutral (W) then at control switch #2 (P) to neutral (W). If 115VAC is present on #1 (LBU) and not on #2 (P), replace control switch. If 115VAC is present on control switch #2 (P), check for 115VAC at HPS (P) to neutral (W) then HPS (BK) to neutral (W). If 115VAC is present at HPS (P) and not at HPS (BK), HPS is open. See HPS Diagnosis below. If 115VAC is present at HPS (BK), check for 10.5VAC at CB K2 #1 red wire to CB K2 #2 red wire. If 10.5VAC is not present, check that the cleaning valve is closed and the interlock switch is closed. Next, check CT continuity. If open, replace CT. b)

HPS Diagnosis:

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, LLV, strainer, check valve, drier, and damaged line set or fitting. 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 12" (30 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.

11

4)

1-Min. Fill Cycle – LED 4 is on.

WV and X11 relay energize. After 1 min., CB checks for a closed FS. If FS is closed, the harvest cycle begins. If harvest cycle begins (Comp, HGV, and FM 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). CB.

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 5a)

Initial Harvest Cycle – LEDs 1, 4, and 2 are on.

WV and X11 relay continue. Comp, FM, HGV, and X10 relay 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 and S5 dip switch 4). WV and X11 relay are energized during harvest for a maximum of 6 min. or the length of harvest minus HPT setting (S4 dip switch 6), 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 K1 #1 or #9 (V) to neutral (W). If 115VAC is not present, check for 115VAC at CB K1 #7 or #10 (LBU) to neutral (W). If 115VAC is present at #7 or #10 (LBU) and not at #1 or #9 (V), replace CB. If 115VAC is present, check for 115VAC at CR or MC solenoid. If 115VAC is present, confirm contacts are closed. If not, replace CR or MC. If CR or MC contacts are closed, check Comp external overload, 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. 12

5b)

Harvest Pump Timer – 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 and S5 dip switch 4). When WV de-energizes, LED 4 turns off, X11 relay de-energizes and LED 3 turns on. PM energizes. Comp, FM, HGV, and X10 relay 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 K1 #6 (O). 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). If 115VAC is not present, replace CB. If 115VAC is present and PM is not energized, check for 115VAC at X10 relay terminal #7 (Y) to neutral (W). If 115VAC is not present, check for 115VAC at X10 relay terminal #3 (P) to neutral (W) and X10 relay terminal #5 (Y) to neutral (W). If 115VAC is present on terminal #3 (P) and not on terminal #5 (Y), replace X10 relay. If 115VAC is present on X10 relay terminal #7 (Y) and PM is not energized, check for 115VAC at X10 relay terminal #4 (R) to neutral (W) and terminal #6 (DBU) to neutral (W). If 115VAC is present on terminal #6 (DBU) and not on terminal #4 (R), replace X10 relay. If 115VAC is present on X10 relay terminal #4 (R), check control switch contact continuity between terminals #4 (R) and #5 (W/R). If contacts are open, replace control switch. If contacts are closed and 115VAC is present between control switch terminal #5 (W/R) and neutral (W), 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 (S4 dip switch 1 & 2 and S5 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 S5 dip switch 4. Maximum harvest time allowed is 20 min.

NOTICE!

S4 dip switch 7 must remain on. Otherwise, PM will not energize during the last seconds of harvest.

6)

Freeze Cycle – LED 1 is on.

Comp, FM, and PM continue. FM and LLV energize. HGV and X10 relay de-energize. Appliance is held in freeze by a 5-min. short cycle protection timer. After 5-min. short cycle protection timer terminates and FS opens, freeze cycle terminates. Note: PM power supply switches from CB K1 #5 (DBU) in harvest to K1 #4 (R) in freeze.

Anti-Slush

: When anti-slush is enabled (S5 dip switch 5 "ON"), PM de-energizes when thermistor reaches 36°F (2.2°C) (5.8kΩ) for 10 sec. then, energizes for the remainder of the freeze cycle.

13

a)

Freeze Cycle Diagnosis

: Confirm Comp, FM, and PM continue. Confirm that FM and LLV energize. Confirm WRV opens. Next, confirm HGV and X10 relay 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 and FM energize, TXV and HM operate correctly, WRV opens, Comp is efficient, and refrigerant charge is correct. See "VIII.A. Specification and Performance Data Sheets." b)

Comp and FM Diagnosis

: If Comp and FM de-energize once freeze begins, check that appliance has not shut off on HPS ("POWER OK" LED off). If so, check "3)b) HPS Diagnosis" above. If CB "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 or MC coil. If 115VAC is present, check CR or MC coil and contact continuity. Replace as needed. If CR or MC is okay, check Comp start relay and start and run capacitors. Next, check Comp motor winding continuity. If Comp is energized but evaporator is not cooling, check for an inefficient Comp. See "VIII.A. Specification and Performance Data Sheets."

FM Diagnosis:

If Comp is energized but FM is not, check CB K1 #1 (V) and #9 (V) wiring circuit for loose connection. If connections are good, check FM capacitor, motor winding, and blade for binding.

c)

WV and HGV Diagnosis

: If WV is energized, check for 115VAC at CB K1 #6 (O) to neutral (W). If 115VAC is present after PM energizes in harvest cycle, replace CB. If 115VAC is not present, replace WV (bypassing). If HGV did not de-energize at the end of harvest, check for 115VAC at CB K1 #2 (P) to neutral (W). If 115VAC is present 50 sec. after PM energizes, replace CB. If 115VAC is not present, replace HGV (bypassing). d)

PM Diagnosis

: Confirm water is flowing over evaporator from PM and not WV. If PM de-energizes once freeze begins, 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 #5 (W/R) to neutral (W). If 115VAC is present at CB K1 #4 (R) and not at control switch #5 (W/R), check control switch continuity between #5 (W/R) and #4 (R). Replace as needed. If 115VAC is present at control switch #5 (W/R) to neutral (W), check PM capacitor and motor winding continuity. e)

LLV Diagnosis

: If LLV does not energize, check for 115VAC at CB K1 #3 (BK) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present, check coil voltage and continuity. f)

Refrigerant Pressures and TXV 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.

14

g)

Freeze Termination Diagnosis:

After 5 min. in freeze, disconnect CB K5 FS connector. 15 sec. later appliance should switch out of the freeze cycle (15 second delay after FS opens before terminating the freeze cycle). If appliance remains in freeze longer than 15 sec. after FS removed, replace CB. If appliance switches with FS removed but would previously not switch out of freeze with FS connected (long freeze - 3 beep alarm), see "II.E. Float Switch Check and Cleaning." Note: Normal freeze cycle will last 20 to 40 min. depending on model and conditions. Cycle times and pressures should follow performance data provided in this manual. See "VIII.A. Specification and Performance Data Sheets." h)

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 CV is not leaking by (water flowing down the potable drain). If CV is leaking by, remove and clean CV, replace rubber seat and spring if necessary. If water tank is full, see "II.E. Float Switch Check and Cleaning." for erratic operating FS.

7)

Pump-Out Cycle – LEDs 1, 3, and 2 are on (10/20 second pump-out).

Timing of the first pump-out is determined by S4 dip switch 5. See the table below.

S4 Dip Switch Setting No. 5

OFF ON

Control Board Settings Pump-Out Frequency

Every 10 cycles Every cycle

Control Board

After 11th freeze cycle After 2nd freeze cycle Comp and FM continue, HGV energize. Note: If S4 dip switch 3 & 4 are set to 3 off and 4 on, LED 4 turns on and WV and X11 relay energize, energizing X10 relay.

pump-out direction.

NOTICE!

 S4 dip switch 3 & 4 must not be set to 3 off and 4 on. Otherwise, PM will rotate in freeze cycle direction instead of

LLV de-energizes. PM stops for 2 sec., then reverses for 10/20 sec. depending on pump-out timer (S4 dip switch 3 & 4) setting. When the pump-out timer terminates, pump-out is complete. The pump-out frequency control (S4 dip switch 5) is factory set, and generally no adjustment is required. However, the pump-out frequency control can be set to have a pump-out occur every 10 cycles or every cycle. For details, see "III.C.4. Pump-Out Frequency Control (S4 dip switch 5)." 15

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 PM stops and re-starts. Next, check that PM rotation is correct (water flowing down the drain through CV). If PM does not stop and re-start, check that CB LEDs 1, 3, and 2 are on. If not, replace CB. If LEDs 1, 3, and 2 are on and PM does not energize, check for 115VAC at CB K1 #5 (DBU) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present, check that X10 relay is de-energized. If not, check X11 relay status. If X11 relay is energized, replace CB. If X11 relay is de-energized and X10 relay is energized, replace X11 relay (contacts sticking). If X10 relay is de-energized, check for 115VAC at terminal #6 (DBU) to neutral (W) and terminal #2 (DBU) to neutral (W). If 115VAC is present on terminal #6 (DBU) and not on terminal #2 (DBU), replace X10 relay. If 115VAC is present on X10 terminal #2 (DBU) and PM is not energized check for 115VAC at X12 terminal #6 (DBU) to neutral (W) and X12 terminal #4 (DBU) to neutral (W). If 115VAC is present on X12 terminal #6 (DBU) and not on X12 terminal #4 (DBU), check for 115VAC at X12 terminal #7 (P) to X12 terminal #8 (W). If 115VAC is not present, check CB K1 pin #2 (P) wiring for loose connection. If 115VAC is present and X12 is not energized, check coil continuity. Replace as needed. If X12 is energized and X12 terminal #4 (DBU) does not have 115VAC, replace X12 relay (contacts sticking). If X12 terminal #4 (DBU) has 115VAC, PM should be energized and rotating in pump-out rotation. If not, check PM motor windings and impeller for binding. If energized and rotating correctly, make sure the drain line is not clogged and that CV is clean and operating properly. Confirm LLV de-energizes. If LLV is energized with LEDs 1, 3, and 2 on, replace CB.

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

1) See "II.D.Bin Control Check." Legend:

BC

–bin control;

CB

–control board;

Comp

–compressor;

CV

–check valve;

FM

–fan motor;

FS

–float switch;

HGV

–hot gas valve;

HPS

–high-pressure switch;

LLV

–liquid line valve;

PM

–pump motor;

TXV

–thermostatic expansion valve;

WV

–inlet water valve 16

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.

Audible Alarm Safeties." Once reset, the icemaker starts at the 1-minute fill cycle. For audible alarm information, see "III.B. LED Lights and 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, check CT primary circuit. Check for 115VAC at CB K1 connector pin #10 (LBU) 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 1, 4, 3, 2. Components (e.g., compressor) cycle during the test.

Control Board

"J"

Correct LED Lighting Sequence

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 17

D. Bin Control Check

BC shuts down the icemaker within 10 sec. when ice contacts the thermostatic bulb, regardless of the cycle at activation.

NOTICE

When the ambient temperature is below 45°F (7°C), BC opens and shuts down the appliance even if the ice storage bin is empty. When BC is set in the prohibited range, the appliance operates continuously even if the ice storage bin is filled with ice. Setting in the prohibited range may result in severe damage to the appliance.

BC is factory set, and generally no adjustment is required. However, adjustment may be needed in some conditions, particularly at higher altitude locations.

Note: A jumper (4A4883G01) must be placed on CB red K4 connector. Otherwise, CB yellow "BC OPEN" LED is on and appliance will not start. To check BC, 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 and base cover, then clear any ice away from BC bulb.

4) Disconnect BC wires from BC switch.

5) Hold your hand around the bulb to warm it up.

6) Check for continuity across BC switch. If closed, continue to step 6. If open, adjust or replace BC.

7) With the multimeter test leads still in place, hold ice on BC bulb to lower the temperature. Within 10 sec., BC switch should open. If it remains closed, adjust or replace BC.

Legend:

BC

–thermostatic bin control 18

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.

Cube Guide

1. Float Switch Check

To check FS, follow the steps below.

1) Turn off the power supply.

Rubber Cap 2) Remove the front panel, then move the control switch to the "OFF" position. 3) Drain the water tank. Remove the front insulation panel, then slide the cube guide to the right. Remove the rubber cap and sleeve covering the overflow pipe. See Fig. 1. Unscrew the overflow pipe. After the water tank has drained, reconnect the overflow pipe. Replace the rubber cap, sleeve, cube guide, and front insulation panel in their correct positions.

NOTICE

! Make sure the O-ring is attached to the bottom of the overflow pipe and be careful not to cross thread the overflow pipe.

Sleeve Overflow Pipe O-Ring

Fig. 1

4) Remove the control box cover. 5) Disconnect FS connector from CB K5 connector.

6) Check for continuity across FS leads. With the water tank empty, FS should be open. If open, continue to step 7. If closed, follow the steps in "II.E.2. Float Switch Cleaning." After cleaning FS, check it again. Replace if necessary.

7) Reconnect FS connector to CB K5 connector, then replace the control box cover in its correct position.

8) Move the control switch to the "ICE" position. Replace the front panel in its correct position, then turn on the power supply. After 1 min., the 1-min. fill cycle should end and the initial harvest cycle should begin. If the initial harvest cycle begins, FS is good and the check is complete. If the initial harvest cycle does not begin, continue to step 9.

9) Turn off the power supply.

10) Remove the front panel. Move the control switch to the "OFF" position.

11) Remove the control box cover.

12) Disconnect FS connector from CB K5 connector. 19

13) 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.

Legend:

CB

–control board;

FS

–float switch

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) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF" position.

3) Drain the water tank. Remove the rubber cap covering the overflow pipe in the water tank. Remove the overflow pipe by turning it counterclockwise. After the water tank has drained, replace the overflow pipe and the rubber cap in their correct positions. Note: Be sure the overflow pipe o-ring is in its correct position on the overflow pipe.

4) Disconnect the vent tube and the flush tube from the top of FS, then remove FS assembly and remove the rubber boot from the bottom of FS assembly. See Fig. 2.

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.

6) Wipe down FS 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 rubber boot and hose with cleaning solution. Rinse the parts thoroughly with clean water.

7) Reassemble FS assembly and replace it and the rubber boot in their correct positions. Reconnect the vent tube and the flush tube.

8) Move the control switch to the "ICE" position. 9) Replace the front panel in their correct positions.

10) Turn on the power supply to start the automatic icemaking process.

Flush Vent Shaft Legend:

CB

–control board;

FS

–float switch Float Switch Housing Float Retainer Rod Rubber Boot and Hose

Fig. 2

20

F. Thermistor Check

To check thermistor resistance, follow the steps below.

1) Turn off the power supply. 2) Remove the front panel. Move the control switch to the "OFF" position.

3) Remove the control box cover.

4) Remove the thermistor from the refrigerant tubing. 5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min.

6) Disconnect the thermistor connector from CB K3 connector and check the resistance between thermistor leads. Normal range is 4.7 to 6.2 kΩ. If outside the normal range, replace the thermistor. See "IV.B. Component Service Information." If within the normal range, continue to the next step.

7) Replace the thermistor in its correct position. See "IV.B. Component Service Information." 8) Reconnect the thermistor connector to CB K3 connector.

9) Replace the control box cover in its correct position.

10) Move the control switch to the "ICE" position. 11) Replace the front panel in its correct position.

12) Turn on the power supply.

13) Once the harvest cycle starts (Comp energizes), begin timing the harvest cycle.

14) The harvest timer and harvest cycle should terminate within 2 to 5 min. If the harvest cycle does not terminate within 2 to 5 min., replace CB.

Legend:

CB

–control board;

Comp

–compressor

G. Control Switch

The control switch has three positions: "OFF" for power off, "ICE" for icemaking, and "WASH" to energize the pump motor when cleaning and sanitizing.

WARNING!

Control switch in "OFF" position does not de-energize all loads

.

Risk of electric shock. Use extreme caution and exercise safe electrical practices.

21

H. Diagnostic Tables

1. No Ice Production No Ice Production - Possible Cause

1. Power Supply a) Off, blown fuse, or tripped breaker.

b) Not within specifications.

2. Main Transformer (208-230/60/1 Models with main transformer and all 208-230/60/3 Models) a) Voltage tap switch not set to proper voltage.

b) Coil winding open or shorted.

3. Fuse (Control Box) a) Blown.

4. Thermostatic Bin Control See "II.D. Bin Control Check" a) Tripped with bin filled with ice.

b) Ambient temperature too cool.

5. Control Switch 6. High-Pressure Switch 7. Control Transformer (115VAC/10.5VAC) 8. Control Board See "II.C. Control Board Check" c) Set too warm.

d) Bulb out of position.

e) Open contacts, defective.

a) In "OFF" or "WASH" position. b) Bad contacts.

a) Dirty condenser.

b) Fan motor not operating.

c) Refrigerant overcharged.

d) Bad contacts.

e) Refrigerant lines or components plugged.

a) Coil winding open or shorted.

9. Water Supply 10. Inlet Water Valve 11. Float Switch See "II.E. Float Switch Check and Cleaning" 12. Compressor a) In alarm.

b) Yellow "BC OPEN" LED on (bin full). K4 Jumper missing or loose.

c) Defective.

a) Water supply off or improper water pressure.

b) External water filters clogged.

a) Screen or orifice clogged.

b) Coil winding open.

c) Water valve open in freeze cycle.

a) Float does not move freely.

b) Defective.

13. Hot Gas Valve 14. Thermistor See "II.F. Thermistor Check" a) Compressor relay/magnetic contactor contacts bad or coil winding open.

b) Start capacitor or run capacitor defective (single phase).

c) Internal protector open.

d) Start relay contacts bad or coil winding open (single phase).

e) Compressor defective.

a) Closed in harvest cycle. b) Open in freeze cycle.

a) Loose, disconnected, or defective.

22

No Ice Production - Possible Cause

15. Pump Motor a) Motor winding open.

b) Bearing worn out or locked rotor.

16. Thermostatic Expansion Valve 17. Liquid Line Valve c) Defective capacitor.

d) Mechanical seal worn out.

a) Bulb loose.

b) Operating erratically.

a) Closed in freeze cycle. b) Open in harvest cycle.

18. Fan Motor 19. Water System a) Motor winding open.

b) Bearing worn out or locked rotor.

c) Defective capacitor.

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

1. Evaporator 2. Cube Guides 3. Spray Tubes and/or Spray Guides 4. Water Supply 5. Inlet Water Valve 6. Float Switch See "II.E. Float Switch Check and Cleaning" 7. Refrigerant Charge 8. Control Board See "III.C. Settings and Adjustments" and "II.C. Control Board Check" 9. Thermistor See "II.F. Thermistor Check" 10. Thermostatic Expansion Valve 11. Hot Gas Valve 12. Liquid Line Valve

Harvest Cycle

a) Scaled up.

b) Damaged.

a) Out of position. b) Damaged.

a) Dirty.

b) Out of position.

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) copper water tubing or equivalent.

a) Screen or orifice clogged.

b) Defective.

a) Dirty, sticking.

b) Defective.

a) Low.

a) Harvest timer (S4 dip switch 1 & 2) set too short.

b) Harvest pump timer (S4 dip switch 7) not in factory default position.

c) Defective.

a) Loose, disconnected, or defective.

a) Defective.

a) Closed or restricted.

a) Open.

23

Freeze-Up - Possible Cause

13. Thermostatic Bin Control See "II.D. Bin Control Check" a) Defective.

1. Evaporator 2. Spray Tubes and/or Spray Guides 3. Refrigerant Charge 4. Control Board See "II.C. Control Board Check" 5. Inlet Water Valve 6. Float Switch See "II.E. Float Switch Check and Cleaning" 7. Pump Motor 8. Thermostatic Expansion Valve 9. Liquid Line Valve

Freeze Cycle

a) Scaled up.

b) Damaged.

a) Dirty.

b) Out of position.

a) Low. a) Freeze timer (S4 dip switch 9 & 10) set incorrectly.

b) Defective.

a) Leaking by.

a) Float does not move freely.

b) Defective.

a) RPM too slow.

b) Impeller damaged.

a) Bulb loose or defective.

a) Restricted.

24

3. Low Ice Production Low Ice Production - Possible Cause

1. Evaporator

Long Harvest Cycle

a) Scaled up.

2. Spray Tubes and/or Spray Guides a) Dirty.

b) Out of position.

3. Refrigerant Charge 4. Water Supply 5. Control Board See "II.C. Control Board Check" a) Low.

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.

a) Thermistor connection loose (K3).

b) Defective.

a) Loose, disconnected, or defective.

6. Thermistor See "II.F. Thermistor Check" 7. Hot Gas Valve 8. Inlet Water Valve 9. Compressor 10. Liquid Line Valve 11. Thermostatic Expansion Valve a) Erratic or closed.

a) Screen or orifice clogged.

a) Inefficient or off.

a) Erratic or open.

1. Evaporator 2. Float Switch See "II.E. Float Switch Check and Cleaning" a) Defective.

Long Freeze Cycle

a) Scaled up, dirty.

a) Scaled up, dirty.

b) Float sticking.

3. Inlet Water Valve 4. Hot Gas Valve 5. Condenser 6. Control Board See "II.C. Control Board Check" 7. Refrigerant Charge 8. Thermostatic Expansion Valve c) Defective switch.

a) Leaking by.

a) Erratic or open.

a) Clogged.

a) Float switch connection loose (K5).

b) Defective.

a) Low. 9. Compressor 10. Pump Motor 11. Liquid Line Valve a) Bulb loose.

b) Defective.

a) Inefficient or off.

a) RPM too slow.

a) Erratic or restricted.

25

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____________Freeze-Up Date___________

List model and manufacture of bin or dispenser__________________________.

Date appliance was last cleaned:__________.

Freeze-Up Defrost

YES NO [ ] [ ] [ ]

Set Up

[ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] 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?_________________.

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_________.

[ ] [ ] 8) Does appliance have any water filtration? If yes please list the following: Filter brand___________________.

Model________________. Filter pressure gauge reading during the fill cycle___________. Date filter was last replaced?__________________________. GPM or LPM flow rate of filter system?__________________.

9) Ambient temperature at appliance? ______________.

At remote condenser (if applicable)?________.

Appliance Status

[ ] [ ] [ ] 10) Is the appliance and/or float switch dirty?

11) List the S4 (1-10) and S5 (1-5) DIP switch settings. S4: 1___2___3___4___5___6___7___8___9___10____ S5: 1_____2_____3_____4_____5______ [ ] 12) Is DIP switch number 7 ON (harvest pump time (harvest assist) all models [ ] [ ] [ ] 13) Are the cube guides 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 splash guards in place?

Appliance Operation Fill

YES NO [ ] [ ] 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 water flow 5GPM for larger?

[ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ]

Harvest

[ ] 20) Is the hot gas valve opening?

[ ] 21) Is harvest pump time (harvest assist) utilized (S4dip switch 7)?

[ ] 22) Is hot gas valve opening in harvest?

[ ] 23) Does water valve close completely when de energized?

24) What was length of harvest?___________.

Freeze

[ ] 25) Is pump motor energized in freeze cycle except during 10-sec. anti-slush. If activated (S5 dip switch 5 on)?

26) Water-cooled condenser outlet temperature 5-min. into freeze? ______________°F. 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) Did appliance shutdown within 10 seconds when ice contacts the bin controls thermostatic bulb? 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 26

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, jumper, and float switch.

• Do not short out power supply to test for voltage.

• Always replace the whole control board assembly if it goes bad.

27

A. Control Board Layout

1. "J" Control Board

"J" Control Board

• Bin Control Switch Closed LED (green)

(on continuously in thermostatic bin control application)

• Bin Control Switch Open LED (yellow)

(mechanical bin control application only)

• "ALARM RESET" Button • Part Number • Alarm Buzzer • S4 Dip Switch • "OUTPUT TEST" Button

(used to test relays on control board)

• K3 (white) Connector

Thermistor (harvest control and high temperature safety)

• POWER OK LED (red)

(lights when 10.5VAC is supplied to K2 connector)

• 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

• K4 (red) Connector

K4 Jumper (thermostatic bin control application)

• S5 Dip Switch • K5 (black) Connector

Float Switch (water level)

Label

(control board revision level indicated on label on side of relay)

• K1 Connector

Pins #1 through #10 #1, 9 Compressor Relay Fan Motor #2 Hot Gas Valve #3 Liquid Line Valve #4 Pump Motor (icemaking) #5 Pump Motor (harvest pump timer and pump-out) #6 Inlet Water Valve #7, 10 Component Power Supply #8 Open

• K2 Connector

Control Transformer (10.5VAC)

"J" Control Board

Part Number 2A7664-04 28

B. LED Lights and Audible Alarm Safeties

Beep occurs and red "POWER OK" LED turns on when control switch is moved to "ICE" position.

Sequence

Green LEDs 1 through 4 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 1, 4, 3, 2.

Sequence Step

1-Minute Fill Cycle Harvest Cycle Harvest Pump Time (harvest assist) Freeze Cycle

LED

4 1, 4, 2 1, 3, 2

Energized Components

WV Comp, FM, HGV, WV Comp, FM, HGV, PM

Time LEDs are On Min.

Max.

1 minute 20 minutes 0 seconds 50 seconds Anti-Slush Control 1 1, 3 Comp, FM, PM, LLV Comp, FM, LLV 5 minutes freeze timer setting If S5 dip switch 5 on, PM off 10 sec. when thermistor at 36°F (2.2°C) 10 seconds 20 seconds Pump-Out Cycle 1, 4 † , 3, 2 Comp, FM, HGV, PM, WV † , DV *FM energized if on K1 Connector Pin #9; † pump-out timer setting

Alarms Type

1 Beep

Alarm

High Evaporator Temp. (temperature > 127°F) (53°C)

Notes

Check for harvest problem (stuck HGV or relay), hot water entering unit, stuck HM, or shorted thermistor. 2 Beep 3 Beep Harvest Backup Timer (harvest > 20 min. for two cycles in a row) Freeze Timer (freeze > freeze timer setting for two cycles in a row) Check thermistor (open), HGV not opening, TXV or LLV leaking by, low charge, inefficient Comp.

Check FS stuck closed (up), WV leaking by, HGV leaking by, PM not pumping, TXV defective, LLV not opening, low charge, or inefficient Comp.

To reset above safeties, press "ALARM RESET" button with power supply on.

6 7 Low Voltage (92Vac±5% or less) High Voltage (147Vac±5% or more) Red LED turns off if voltage protection operates. Control voltage safeties automatically reset when voltage is corrected.

Legend:

CB

–control board;

Comp

–compressor;

FM

–fan motor;

FS

–float switch;

HGV

–hot gas valve;

HM

–headmaster (C.P.R.);

LLV

–liquid line valve;

PM

–pump motor;

TXV

–thermostatic expansion valve;

WV

–inlet water valve 29

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:

S4 Dip Switch No.

KM-1100MAJ50

1 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.

1 2 3 4

KM-1100MAJ50

5

OFF OFF OFF OFF ON

S4 Dip Switch "J" Control Boards

Freeze Timer (9 & 10) Factory Use (8) Harvest Pump Time (Harvest Assist) (7) (Do Not Adjust) Harvest Pump Time (Harvest Assist Duration) (6) (Do Not Adjust) Pump-Out Frequency Control (5) Pump-Out Time/Harvest Time During Pump-Out (3 & 4) Harvest Timer (1 & 2)

S5 Dip Switch "J" Control Board Only

Do Not Adjust Anti-Slush (5) Minimum Harvest Time (4) Refill Counter (2 and 3) Float Switch Selector (1) 30

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

OFF OFF ON OFF ON OFF ON ON

Time (sec.)

60 90 120 180

3. Pump-Out Timer/Harvest Time During Pump-Out (S4 dip switch 3 & 4)

NOTICE

• On models with harvest pump timer, do not adjust 3 off and 4 on. Pump does not run in pump-out rotation in this setting.

When a pump-out is called for, the pump motor stops for 2 sec., then energizes in the reverse direction, taking water from the bottom of the water tank and forcing pressure against the check valve seat allowing water to go through the check valve and down the drain. At the same time, water flows through the small tube to power flush the float switch. 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 T1 No. 3

OFF ON OFF ON

No. 4

OFF OFF ON ON 10 10 10 20 T1: Time to drain the water tank T2: Harvest timer at pump out

Time (sec.) T2 S5-4 OFF S5-4 ON

150 100 180 120 180 130 70 180 31

Inlet Water Valve S5-4 OFF S5-4 ON

Closed Closed Closed Open Closed Closed Closed Closed

4. Pump-Out Frequency Control (S4 dip switch 5)

The pump-out frequency control is factory set to drain the water tank every 10 cycles.

Generally no adjustment is required. However, where water quality is bad and the icemaker needs a pump-out more often, the pump-out frequency can be adjusted. The pump-out frequency control can be set to have a pump-out occur every cycle, or every 10 cycles.

The first pump-out is dependent on S4 dip switch 5. See the table below.

S4 Dip Switch Setting No. 5

OFF ON

Pump-Out Frequency

Every 10 cycles Every cycle

1st Pump-Out

After 11th freeze cycle After 2nd freeze cycle

5. Harvest Pump Time (Harvest Assist Duration) (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. Harvest pump time (harvest assist duration) is only active when S4 dip switch 7 is in the "ON" position. In the factory default position, the harvest pump time (harvest assist duration) starts with 50 sec. left to go in harvest cycle (S4 dip switch 6) and 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 (harvest assist duration) is factory set, and no adjustment is required.

S4 Dip Switch Setting No. 6

OFF ON

Harvest Pump Time (Harvest Assist) S5-4 OFF S5-4 ON

50 sec.

25 sec.

25 sec.

15 sec.

32

6. Harvest Pump Time (Harvest Assist) (S4 dip switch 7)

NOTICE

Factory set for proper operation. Do not adjust. Adjustment outside of the factory default setting may result in damage to the appliance. a) Harvest Pump Time (Harvest Assist) Depending on S4 dip switch 7 setting, the pump motor either stays off or is energized during the last seconds of the harvest cycle. When the pump motor is energized (S4 dip switch 7 on), water circulates over the evaporator. The harvest water valve is open during harvest for a maximum of 6 minutes or the length of harvest minus the harvest pump time value (S4 dip switch 6), whichever is shorter. When S4 dip switch 7 is in the on position and harvest begins, X11 and X10 relays energize. A latching circuit is created through the X11 and X10 relays. For further details, see "VIII.B. Wiring Diagrams." In the factory default position, 50 sec. before harvest termination, LED 4 turns off, inlet water valve and X11 relay de-energize. X10 relay remains energized through the latching circuit. Next, LED 3 turns on and control board K1 connector pin #5 (DBU wire) energizes, energizing the pump motor for the last seconds of harvest. Harvest pump time adjusted by S4 dip switch 1 & 2 and S5 dip switch 4 settings. Contact Technical Support before adjusted these settings.

S4 Dip Switch Setting Harvest Pump Time No. 7 (Harvest Assist)

OFF ON Disabled Enabled

7. Factory Use (S4 dip switch 8)

Factory set for proper operation. Do not adjust. This must be left in the factory default position.

33

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.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.

S4 Dip Switch Setting No. 9 No. 10

OFF OFF OFF ON ON ON OFF ON

Time (min.)

60 50 70 75

9. Float Switch Selector (S5 dip switch 1)

NOTICE

Do not adjust. This must be left in the factory default position or the icemaker will not operate correctly.

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.

S5 Dip Switch Setting Top or Bottom Float Switch No. 1 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.

S5 Dip Switch Setting No. 2 No. 3

OFF OFF OFF ON ON ON OFF ON

Refill Counter

0 1 refill 9 refills 10 refills 34

11. Minimum Harvest Time (S5 dip switch 4)

NOTICE

Factory set for proper operation. Do not adjust. Adjustment outside the factory default setting may result in damage to the appliance.

S5 Dip Switch Setting No. 4

OFF ON

Minimum Harvest Timer

120 sec.

70 sec.

12. Anti-Slush (S5 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.

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 ice slush and prevent ice slush from blocking the water supply tubing, causing irregular freeze patterns.

S5 Dip Switch Setting No. 5

OFF ON

Anti-Slush

Disabled Enabled 35

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.

36

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.

37

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.

38

B. Component Service Information

NOTICE

When replacing a component listed below, see the notes to help ensure proper operation.

Component

Compressor Thermostatic Expansion Valves Hot Gas Valves Liquid Line Valves Fan Motors Pump Motor Thermistor

Notes

1 phase: Install a new start capacitor, run capacitor, and start relay.

3 phase: Install a new magnetic contactor.

• Attach the thermostatic expansion valve bulb to the suction line in the same location as 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.

• Replace the strainer if applicable.

• Use copper tube of the same diameter and length when replacing valve lines.

Install a new capacitor.

Install a new capacitor.

• 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.

39

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 Monthly Scoop Bi-Weekly Air Filters External Water Filters 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.

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.

Yearly Underside of Icemaker and Top Kits; Bin Door and Snout Icemaker and Dispenser Unit/Ice Storage Bin Liner Wipe down with a clean cloth and warm water.

Clean and sanitize per the cleaning and sanitizing instructions provided 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. 40

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.

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 since you turned off the power supply. Make sure the control switch is in the "ICE" position. Replace the front panel in its correct position, then turn on the power supply.

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.

41

2. Remove the water from the water tank:

1) Turn off the power supply, then remove the front panel.

2) Move the control switch to the "OFF" position.

3) Drain the water tank. Remove the rubber cap covering the overflow pipe in the water tank. Remove the overflow pipe by turning it counterclockwise. After the water tank has drained, replace the overflow pipe and the rubber cap in their correct positions.

NOTICE

! Make sure the O-ring is attached to the bottom of the overflow pipe and be careful not to cross thread the overflow pipe.

4) Replace the base cover (if applicable) and front panel in their correct positions.

5) Remove all ice from the dispensing unit/ice storage bin. Clean the storage bin liner using a neutral cleaner. Rinse thoroughly after cleaning.

Cube Guide Rubber Cap Sleeve Overflow Pipe O-Ring

Fig. 3

42

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. 43

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-1100MAJ50 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.) FOR THE EUROPEAN MARKET ICE CAPACITY lbs./day (kg/day) SHAPE OF ICE ICE PRODUCTION PER CYCLE BIN CONTROL SYSTEM REFRIGERANT CHARGE 220-240/50/1 11.2 A ( 5 Min. Freeze AT 104°F / WT 80°F) 20 A 20 A 90/70°F 1850(5.65) 149(19.0) Crescent Cube 19.2 lbs. (8.7 kg) 960pcs.

Thermostat R404A, 3 lb. 1.4 oz. (1400g) 70/50°F 1710(4.00) 716(70.0) 10/10°C 20/15°C 30/25°C 1035 (470)1006 (456) 797 (362)

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 m FREEZING CYCLE TIME min.

min.

3 /day HARVEST CYCLE TIME HEAD PRESSURE PSIG kg/cm PSIG kg/cm 2 2 G SUCTION PRESSURE G AMBIENT TEMP. (ºF/ºC) 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 70/21 80/27 90/32 100/38 TOTAL HEAT OF REJECTION FROM CONDENSER TOTAL HEAT OF REJECTION FROM COMPRESSOR

250

267 272 279

52

53 53 55

1023

970 953 952 50/10

1710

1741 1751 1620

716

589 550 373

20

23 24 23

6.9

5.8

5.5

4.0

464 440 432 432 2.71

2.23

2.08

1.41

17.6

18.7

19.1

19.6

3.7

3.7

3.8

3.9

WATER TEMP. (ºF/ºC) 70/21 953 861

784

772 432 391 356 350 1751 1805

1850

1780 550 331

149

149 2.08

1.25

0.56

0.56

24 30

34

34 5.5

3.6

2.0

2.0

272 300

324

332 53 55

57

58 19.1

21.1

22.8

23.3

3.8

3.9

4.0

4.1

304 335 358 390 58 62 63 68 891 817 731 682 90/32 1543 1450 1553 1280 495 373 148

148

26 29 35 35 5.0

4.0

2.0

2.0

404 371 332 309 1.88

1.41

0.56

0.56

21.4

23.5

25.2

27.4

4.1

4.3

4.4

4.8

12,600 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 2,200 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)] 44 ENG.F-011.1.0205

B. Wiring Diagram

1. KM-1100MAJ50

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