Hoshizaki KM-520MAJ-E Service Manual

Service Manual
Modular Crescent Cuber
Models
KM-520MAJ-E
KM-660MAJ-E
hoshizakiamerica.com
Number: 73232
Issued: 10-11-2018
WARNING
Only qualified service technicians should install and service the icemaker. To
obtain the name and phone number of your local Hoshizaki Certified Service
Representative, visit www.hoshizaki-europe.com. No service should be undertaken
until the technician has thoroughly read this Service Manual. Failure to service and
maintain the icemaker in accordance with this manual will adversely affect safety,
performance, component life, and warranty coverage and may result in costly water
damage. Proper installation is the responsibility of the installer. Product failure or
property damage due to improper installation is not covered under warranty.
Hoshizaki provides this manual primarily to assist qualified service technicians in the
service and maintenance of the icemaker. Should the reader have any questions or
concerns which have not been satisfactorily addressed, please call the appropriate
Hoshizaki Service Office:
UK/Ireland - Hoshizaki UK
TEL : +44 (0)845 456 0585
FAX: +44 (0)132 283 8331
Holland - Hoshizaki Europe
TEL : +31 (0)20 6918499
FAX: +31 (0)20 6918768
Belgium/Luxemburg - Hoshizaki Belgium
TEL : +32 (0)2 7123030
FAX: +32 (0)2 7123031
Germany/Switzerland/Austria - Hoshizaki Deutschland
TEL : +49 (0)2154 92810
FAX: +49 (0)2154 928128
France - Hoshizaki France
TEL : +33 (0)1 48639380
FAX: +33 (0)1 48639388
Other countries - Hoshizaki Europe
TEL: +31 (0)20 6918499
FAX: +31 (0)20 6918768
Web Site: www.hoshizaki-europe.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
B. Water/Refrigeration Circuit Diagram............................................................................... 8
II. Sequence of Operation and Service Diagnosis.................................................................. 9
A. Sequence of Operation Flow Chart................................................................................ 9
1. Operation Flow Chart ............................................................................................... 9
2. Shutdown Flow Chart............................................................................................. 10
B. Service Diagnosis.........................................................................................................11
C. Control Board Check.................................................................................................... 17
D. Bin Control Check and Adjustment............................................................................... 18
E. Float Switch Check and Cleaning................................................................................ 21
F. Thermistor Check.......................................................................................................... 23
G. Control Switch.............................................................................................................. 23
H. Mode Switch................................................................................................................ 23
I. Diagnostic Tables........................................................................................................... 24
J. Freeze-Up Check List................................................................................................... 28
III. Controls and Adjustments................................................................................................ 29
A. Control Board Layout................................................................................................... 30
B. LED Lights and Audible Alarm Safeties........................................................................ 31
C. Settings and Adjustments............................................................................................. 32
1. Default Dip Switch Settings..................................................................................... 32
2. Harvest Time (S4 dip switch 1 & 2)........................................................................ 33
3. Pump-Out Time/Harvest Time During Pump-Out (S4 dip switch 3 & 4).................. 33
4. Pump-Out Frequency Control (S4 dip switch 5)...................................................... 34
5. Harvest Pump Time (Harvest Assist Duration) (S4 dip switch 6)............................ 34
6. Harvest Pump Time (Harvest Assist) (S4 dip switch 7)......................................... 35
7. Factory Use (S4 dip switch 8)................................................................................. 35
8. Freeze Timer (S4 dip switch 9 & 10)....................................................................... 36
9. Pump-Out Pump Motor Direction (S5 dip switch 1)................................................ 36
10. Refill Counter (S5 dip switch 2 and 3)................................................................... 37
11. Minimum Harvest Time (S5 dip switch 4).............................................................. 37
12. Slush Control (S5 dip switch 5)............................................................................. 37
IV. Refrigeration Circuit and Component Service Information.............................................. 38
A. Refrigeration Circuit Service Information..................................................................... 38
B. Component Service Information................................................................................... 41
V. Maintenance..................................................................................................................... 42
VI. Preparing the Appliance for Periods of Non-Use............................................................. 43
VII. Disposal.......................................................................................................................... 44
3
VIII. Technical Information..................................................................................................... 45
A. Specification and Performance Data Sheets................................................................ 45
1. KM-520MAJ-E......................................................................................................... 45
2. KM-660MAJ-E........................................................................................................ 46
B. Wiring Diagrams .......................................................................................................... 47
1. KM-520MAJ-E, KM-660MAJ-E............................................................................... 47
4
Important Safety Information
Throughout this manual, notices appear to bring your attention to situations which could
result in death, serious injury, damage to the appliance, or damage to property.
WARNING
Indicates a hazardous situation which could result in death or
serious injury.
NOTICE
Indicates a situation which could result in damage to the
appliance or property.
IMPORTANT
Indicates important information about the use and care of the
appliance.
WARNING
The appliance should be destined only to the use for which it has been expressly
conceived. Any other use should be considered improper and therefore dangerous.
The manufacturer cannot be held responsible for injury or damage resulting from
improper, incorrect, and unreasonable use. Failure to service and maintain the
appliance in accordance with this manual will adversely affect safety, performance,
component life, and warranty coverage and may result in costly water damage.
To reduce the risk of death, electric shock, serious injury, or fire, follow basic
precautions including the following:
• Only qualified service technicians should install and service this appliance.
• The appliance must be installed in accordance with applicable national, state, and
local codes and regulations.
• Electrical connection must be hard-wired and must meet national, state, and local
electrical code requirements. Failure to meet these code requirements could result
in death, electric shock, serious injury, fire, or 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.
5
WARNING, continued
• Children should be properly supervised around this appliance.
• Do not climb, stand, or hang on the appliance or allow children or animals to do so.
Serious injury could occur or the appliance could be damaged.
• Do not use combustible spray or place volatile or flammable substances near the
appliance. They might catch fire.
• Keep the area around the appliance clean. Dirt, dust, or insects in the appliance
could cause harm to individuals or damage to the appliance.
NOTICE
• Follow the instructions in this manual carefully to reduce the risk of costly water
damage.
• In areas where water damage is a concern, install in a contained area with a floor
drain.
• Install the appliance in a location that stays above freezing. Normal operating
ambient temperature must be within 45°F to 100°F (7°C to 38°C).
• Do not leave the icemaker on during extended periods of non-use, extended
absences, or in sub-freezing temperatures. To properly prepare the icemaker for
these occasions, follow the instructions in "VI. Preparing the Appliance for Periods
of Non-Use."
• Do not place objects on top of the appliance.
• The dispenser unit/ice storage bin is for ice use only. Do not store anything else in
the dispenser unit/ice storage bin.
6
I. Construction and Water/Refrigeration Circuit Diagram
A. Construction
1. Air-Cooled Models (MAJ-E)
Drain Valve
Water Supply Inlet
Cleaning Valve
Spray Tubes
Stainer
Hot Gas Valve
Evaporator
Condenser
High-Pressure
Switch
Inlet Water Valve
Thermostatic
Expansion Valve
Fan Motor
Liquid Line
Valve
Float Switch
Drier
Bin
Control
Compressor
Water Pump
Control Box
Control Switch
Mode Switch
Model Shown: KM-520MAJ
7
Drain
Evaporator
8
Water Circuit
Refrigeration Circuit
Water Tank
Float Switch
Spray Tubes
Water Pump
Drain Valve
Bypass Valve
Thermistor
Water Supply
Inlet Water Valve
Drier
Compressor
Suction Line
Discharge Line
Thermostatic Expansion Valve
Heat
Exchanger
Liquid Line Valve
Fan
Condenser
Strainer
Hot Gas
Valve
High-Pressure
Switch
B. Water/Refrigeration Circuit Diagram
1. Air-Cooled Models (MAJ-E)
Comp energized
HGV energized
WV energized
FS closed
Thermistor
in control
FS check
9
Slush Control
Thermistor temperature
reaches 36°F (2.2°C)
(5.8 kΩ).
PM de-energized for 10 sec.
FS opens or freeze
timer terminates
FS in control
Comp energized
DV energized
HGV energized
PM de-energizes for 2 sec.,
then energizes for 10/20 sec.
FM de-energized
LLV de-energized
• Factory set for every 10th
cycle
(S4 dip switch 5)
• Pump motor
de-energizes for 2 sec.,
then energizes for
10/20 sec.
(S4 dip switch 3 & 4)
4. Pump-Out Cycle
• When the control switch is in the "ON" position and the mode switch is in the "CLEAN" position power is supplied to the control board K9 connector. The control board
then initiates a clean/sanitze program. See the maintenance label on the top cover or the instruction manual for details.
• When the control switch is in the "PUMP" position and the mode switch is in the "CLEAN" position, only the pump motor energizes and circulates water tank contents
over outside of evaporator plate assembly as the control board power supply has been disconnected. The Clean/Sanitize program cannot initiate in this scenario.
Components Energized when the Control Switch is in the "ON" or "PUMP" position and the Mode Switch
is in the "CLEAN" Position
When the control switch is in the "PUMP" position power is supplied to the pump motor. Water tank contents then flows over the outside of the
evaporator plate assembly. Note: Water tank contents does not flow inbetween the evaporator plates.
Comp energized
FM energized
PM energized
LLV energized
HGV de-energized
FS closed
5-min.
minimum
freeze timer in
control
• Min. freeze time: 5 min.
• Max. freeze time: freeze timer setting (S4 dip
switch 9 & 10).
3. Freeze Cycle
Components Energized when the Control Switch is in the "PUMP" Position
FS open
Thermistor temperature reaches
48°F (9°C) (3.9 kΩ or less).
Harvest timer starts.
PM energized
WV de-energized
50 sec.
Harvest Pump
Timer
1 to 3-min. harvest timer in
control (S4 dip switch 1 & 2)
• WV time: 6 min. or the length of harvest minus 50 sec.
(S4 dip switch 7), whichever is shorter. Do not adjust S4
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:
BC–bin control
Comp–compressor
DV–drain valve
FM–fan motor
FS–float switch
HGV–hot gas valve
LLV–liquid line valve
PM–pump motor
WV–inlet water valve
Startup
Cycle
Steps
Operation Flow Chart
II. Sequence of Operation and Service Diagnosis
A. Sequence of Operation Flow Chart
BC Operation
Shutdown
and Restart
10
Legend:
BC–bin control
BC open (BC sensor engaged)
Green UBC LED off
Yellow "BC OPEN" LED on
All components
de-energized.
2. Icemaker Off
BC closed
(BC sensor disengaged)
Green UBC LED on
Yellow "BC OPEN" LED off
To 1. 1-Minute Fill Cycle
Icemaker starts at
"1. 1-Minute Fill Cycle."
3. Ice Level Lowered
Control board retains freeze-time correction count data
between bin control restarts.
Yellow "BC OPEN" LED continues. All
components de‑energized.
Shutdown Delay:
• Fill Cycle–15 sec. after activation.
• Harvest Cycle–At the end of the harvest cycle, or up
to 15 sec. into the freeze cycle if
activated at the end of the harvest cycle.
• Freeze Cycle– 15 sec. after activation if activated at least
15 sec. before the 5-min. short cycle
protection timer terminates.
Otherwise, at the end of the next harvest
cycle.
1. Bin Full
Shutdown Flow Chart
2. Shutdown Flow Chart
B. Service Diagnosis
WARNING
• The appliance should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
• Risk of electric shock. Control switch in "OFF" position does not de‑energize all
loads Use extreme caution and exercise safe electrical practices.
• Moving parts (e.g., fan blade) can crush and cut. Keep hands clear.
• Before servicing the appliance, move the control switch to the "OFF" position and
turn off the power supply.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are
securely in place after the appliance is serviced. Make sure that none have fallen
into the dispenser unit/ice storage bin.
• Make sure all food zones in the appliance and dispenser unit/ice storage bin are
clean after service.
The diagnostic procedure is a sequence check that allows you to diagnose the electrical
system and components. Before proceeding, check for correct installation, proper voltage
per nameplate, and adequate water supply. Check CB using the steps in "II.C. Control
Board Check." Check dip switch settings to assure that S4 dip 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: • When checking high voltage (230VAC), check electrical outlet power supply and
confirm 13A power supply cord fuse is good.
• Main transformer; The 115VAC neutral (W) for components is provided through
the main transformer. To confirm a good 115VAC neutral (W), check for 60VAC
from white (W) neutral to ground/earth (GND (EARTH)). If 60VAC is present,
main transformer and neutral is good. If 60VAC is not present, check 230VAC
main power supply to the main transformer. If 230VAC is present at the electrical
outlet, check power supply cord fuse and main transformer continuity.
• When checking component high voltage (115VAC), always choose a white (W)
neutral wire to establish a good neutral connection.
• When checking voltage from the CB K1 connector (10 pin connector), pull
CB K1 connector out slightly to allow room for multimeter test leads contact.
1) Remove the front panel, then move the control switch to the "OFF" position. Next,
unplug the power supply cord from the electrical outlet. Access the control box and
check that the 115VAC 10A fuse is good.
2) Clear ice from BC sensing area.
11
1. Sequence and Component Diagnosis
3) Power On: Plug the power supply cord back into the electrical outlet, then move the
control switch to the "ON" position and the mode switch to the "ICE" position.
A 5‑sec. delay occurs. CB red "POWER OK" LED turns on. If CB yellow "BC
OPEN" LED is on (indicating a full bin), move ice away from BC sensing area or
see "II.D. Bin Control Check and Adjustment."
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" or
BC using steps in "II.D. Bin Control Check and Adjustment."
a) Power On Diagnosis: If CB red "POWER OK" LED is off, confirm 10A fuse is good.
Check for 115VAC at control switch #2 (BK) to neutral (W) then at control switch #1 (P)
to neutral (W). If 115VAC is present on #2 (BK) and not on #1 (P), replace control
switch. If 115VAC is present on control switch #1 (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 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, 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 6" (15 cm) clearance at rear, sides, and top for proper air circulation and ease of
maintenance and/or service should they be required.
• The appliance should not be located in a corrosive environment.
4) 1-Min. Fill Cycle – LED 4 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 and HGV
energize), 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 K1 #6 (O) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is
present, and WV does not energize, check for 115VAC at WV. If 115VAC is present,
check coil continuity. If open, replace WV. If the water tank fills, but the appliance fails to
start harvest (Comp energized), check for open FS. See "II.E. Float Switch Check and
Cleaning." If FS is closed and CB fails to start the harvest cycle after 1 min., replace CB.
12
5a) Initial Harvest Cycle – LEDs 1, 4, and 2 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 (S4 dip switch 1 &
2 and S5 dip switch 4). WV is 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 #9 (Y) to neutral (W). If 115VAC is not
present, check for 115VAC at CB K1 #10 (BK) to neutral (W). If 115VAC is present
at #10 (BK) and not at #9 (Y), replace CB. If 115VAC is present, check for 115VAC
at mode switch #2 (Y) to neutral and mode switch #1 (V) to neutral. If 115VAC is
present at #2 (Y) and not at #1 (V), confirm mode switch is in "ICE" position. If in
"ICE" position, check mode switch continuity. If open, replace mode switch. If 115VAC
is present at mode switch #1 (V), 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 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, check for 115VAC at CB K1 #1 (V). If 115VAC is not present,
check wiring for loose connection from CB 10 pin connector pin #1 (V) to mode
switch. If 115VAC is present on #1 (V) and not at #2 (P), replace CB.
If 115VAC is present at #2 (P), check for 115VAC at HGV coil and check HGV coil
continuity. Replace as needed. Note: LED is off when HGV is energized and on when
LLV/FM are energized.
c) LLV Diagnosis: Confirm that LLV is de-energized and closed (not bypassing).
If energized, replace CB. If de-energized and bypassing, replace LLV.
5b) Harvest Pump Time (Harvest Assist) – LEDs 1 and 3 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 and LED 3 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 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 #4 (R). If 115VAC is not present, replace
CB. If 115VAC is present and PM is not energized, check PM capacitor and motor
winding continuity.
13
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, 2, and 3 are on. Comp and PM continue. FM and LLV energize.
HGV de‑energizes. 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 continues from CB K1 #4 (R) in harvest and in freeze.
Slush Control: When slush control is enabled (S5 dip switch 5 "ON"), PM de-energizes
when thermistor reaches 36°F (2.2°C) (5.8 kΩ) for 10 sec. then, energizes for the
remainder of the freeze cycle.
a) Freeze Cycle Diagnosis: Confirm Comp and PM continue. Confirm that FM and
LLV energize. Next, confirm HGV de-energizes. 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 operates correctly,
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 K1 #9
(Y) to neutral (W). If 115VAC is not present and LED 1 is on, replace CB. If 115VAC
is present, check for 115VAC at CR coil. If 115VAC is present, check CR coil and
contact continuity. Replace as needed. If CR is okay, check Comp external overload,
Comp start and run capacitors, Comp start relay, and Comp motor winding. 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 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 and LED 2 is on, 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 PM capacitor and motor winding continuity. Except for 10 sec. slush control.
14
e) FM and LLV Diagnosis: If FM or LLV does not energize, check for 115VAC at CB
K1 #3 (BK) to neutral (W). If 115VAC is not present and LED 2 is on, check for
115VAC at CB K1 #1 (V). If 115VAC is present at #1 (V) and not at #3 (BK), replace
CB. If 115VAC is present and LED 2 is on:
For FM, check capacitor, motor winding, and blade for binding.
For LLV, check coil voltage and continuity.
Note: LED 2 is on for LLV/FM and off for HGV.
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.
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 DV is not leaking by (water flowing down the drain). If DV is leaking by, remove
and clean DV, replace if necessary. If water tank is full, see "II.E. Float Switch Check
and Cleaning." for erratic operating FS.
15
7) Pump-Out Cycle – LEDs 1, 3, and 5 are on (10/20 second pump-out). Timing of the
first pump-out is determined by S4 dip switch 5. See the table below.
Control Board Settings
S4 Dip Switch Setting
Pump-Out Frequency
Control Board
OFF
Every 10 cycles
After 11th freeze cycle
ON
Every cycle
After 2nd freeze cycle
No. 5
Comp continues, HGV energizes.
Note: If S4 dip switch 3 & 4 are set to 3 off and 4 on, LED 4 turns on and WV energizes.
NOTICE! S5 dip switch 1 must not be adjusted. This is the pump-out circulation
selection and allows DV to energize in pump-out.
FM and LLV de‑energize. PM stops for 2 sec., then PM and DV energize for 10/20 sec.
depending on pump‑out timer (S4 dip switch 3 & 4) setting. When the pump‑out timer
terminates, pump‑out is complete. The pump-out frequency control (S4 dip switch 5) is
factory set, and generally no adjustment is required. However, the pump‑out frequency
control can be set to have a pump-out occur every 10 cycles or every cycle. For details,
see "III.C.4. Pump‑Out Frequency Control (S4 dip switch 5)."
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 and DV energized (water flowing down the
drain through DV). If PM does not stop and re-start, check that CB LEDs 1, 3, and
5 are on. If not, replace CB. If LEDs 1, 3, and 5 are on and PM does not energize,
check for 115VAC at CB K1 #4 (R) to neutral (W). If 115VAC is not present, replace CB.
If not, check PM motor windings and impeller for binding. If energized, make sure DV
energized. If not, check for 115VAC at CB K1 #5 (W/BU). If 115VAC is not present and
LED 5 is on, replace CB. If 115VAC is present, check DV solenoid continuity. Replace as
needed. If DV is energized and open, check that the drain line is not clogged.
Confirm FM and LLV de-energize. If FM or LLV are energized with LEDs 1, 3, and 5 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 Diagnosis
1) See "II.D.1. Bin Control Check."
Legend: BC–bin control; CB–control board; Comp–compressor; CT–control transformer;
DV–drain valve; FM–fan motor; FS–float switch; HGV–hot gas valve;
HPS–high-pressure switch; LLV–liquid line valve; MT–main transformer;
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. Once reset, the icemaker starts at the
1-minute fill cycle. For audible alarm information, see "III.B. LED Lights and
Audible Alarm Safeties."
1) Check the dip switch settings to assure that S4 dip switch 3, 4, 7, 8, 9, 10 and S5 dip
switch 1 through 5 are in the factory default position. S4 dip switch 1, 2, 5, and 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 "ON" position and the mode 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 MT primary circuit and 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 incoming power supply
circuit (power supply, power supply cord fuse, MT, 10A fuse, and CT primary circuit).
Check for 115VAC at CB K1 connector pin #10 (BK) 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.I.1. No Ice Production."
3) The "OUTPUT TEST" button provides a relay sequence test. Make sure the control
switch is in the "ON" position and the mode 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, 5, 3, 2.
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) 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
ALARM
RESET
OUTPUT
TEST
(W wire). If output voltage is not found and the
appropriate
LED is on,
replace
CB.
S3
Pin #
VDC
Pin #
VDC
#1 to #2
5VDC
#1 to #2
1.2VDC
#1 to #3
5VDC
#1 to #3
5VDC
#1 to #3
#2 to #3
0VDC
#2 to #3
0VDC
WHITE
1
K7
LED 2
K4
2VDC
1 2 3 4 5
BLACK
1
ON
Float Switch
3
1.2VDC
K5
17
P/N 2A3792-01
#2 to #3
WER
K
Jumper
RED
VDC
5VDC
K6
Pin #
#1 to #2
3
K5 Float Switch
K1
K4 Jumper
S5
K3 Thermistor
K3
1
3
CB
1
S4
BC CLOSED
BC OPEN
ON
Legend: CB–control board; CT–control transformer
1 2 3 4 5 6 7 8 9 10
S2
5) Check CB control connectors K3, K4, and K5 for correct VDC per table below.
Note: Pin #1 is DC ground (GND) on each connector
Thermistor
D. Bin Control Check and Adjustment
WARNING
• All parts are factory-adjusted. Improper adjustments may adversely affect safety,
performance, component life, and warranty coverage.
• In Hoshizaki DB and DM dispenser applications, the bin control controller setting
must be adjusted to 2. For Coca-Cola Freestyle® Dispenser and other dispenser
applications, the bin control controller setting must be adjusted to 3. Increasing
the ice level on any dispenser application could lead to icemaker movement,
water leakage, or ice overflow.
NOTICE
• Do not block the bin control lens with top kits or the icemaker will not operate
properly.
• Failure to properly adjust the bin control setting could result in water leakage, ice
backup, and icemaker damage.
1. Bin Control Check
The bin control is factory set for use on Hoshizaki America standard ice storage bins.
If mounted on a dispenser application or if a change to the ice level in an ice storage bin
application is desired, see "II.D.2. Bin Control Adjustment."
1) Remove the front panel and base cover. See Fig. 1.
2) Move the control switch to the "OFF" position.
3) Confirm the mode switch is in the "ICE" position, then move the control switch to the
"ON" position. See Fig. 2. Turn on the power supply, and allow the icemaker to operate.
Control Switch
Base Cover
Fig. 1
Mode Switch
Fig. 2
18
4) As water begins to fill the water tank (1-min. fill), place an object 5" to 7" (127 to
178 mm) away from the bin control lens. See Fig. 3. 15 sec. later, the icemaker shuts
down. Remove the object from the bin control lens. 30 sec. later, the icemaker restarts.
Bin Control Lens
Fig. 3
Cycle at Bin
Shutdown
Control Activation
Fill Cycle
15 sec. after activation.
Harvest Cycle
If engaged 15 sec. or longer, at the end of 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.
Ice Level in Bin
Control Board
"OPEN/CLOSED" LED
Bin Control Controller
LED 1
Empty
OFF
ON
Full
ON
OFF
5) Once the icemaker restarts, move the control switch to the "OFF" position, then turn off
the power supply.
6) Replace the base cover in its correct position.
7) Move the control switch to the "ON" position. Replace the front panel in its correct
position, then turn on the power supply.
19
2. Bin Control Adjustment
WARNING
• All parts are factory-adjusted. Improper adjustments may adversely affect safety,
performance, component life, and warranty coverage.
• In Hoshizaki DB and DM dispenser applications, the bin control controller setting
must be adjusted to 2. For Coca-Cola Freestyle® Dispenser and non-Hoshizaki
dispenser applications, the bin control controller setting must be adjusted to 3.
Increasing the ice level on any dispenser application could lead to icemaker
movement, water leakage, or ice overflow.
NOTICE
• Do not block the bin control lens with top kits or the icemaker will not operate
properly.
• Failure to properly adjust the bin control setting could result in water leakage, ice
backup, and icemaker damage.
The bin control is factory set to 1 for use on Hoshizaki America standard ice storage bins.
See the table below for adjustments to ice level.
WARNING! Do not adjust outside of these settings.
1) If not already removed, remove the front, top, and right side panels.
2) Confirm bin control controller setting for proper application. See the table below for
settings. See Fig. 4 for ice level reference.
Application
Default: Standard Ice Storage Bins
Hoshizaki DB and DM Dispensers
Coca-Cola Freestyle® Dispenser and
Non-Hoshizki Dispensers
Optional Settings
Recommended Setting for
Hoshizaki DB or DM Dispenser
Bin Control Ice Level Settings
Bin Control Controller
Ice Detection Distance From
Setting
Bin Control Lens
1
254 mm (10")
2
305 mm (12")
3
406 mm (16")
4
5
508 mm (20")
610 mm (24")
Recommended Setting for
Coca-Cola Freestyle® Dispenser
and Non-Hoshizaki Dispensers
Factory Default for
Standard Ice Storage Bins
Bin Control Lens
Setting #1
Setting #2
Setting #3
Setting #4
Setting #5
Bin Control
Controller
Model Shown:
KM-660MAJ-E with B-300SF
Fig. 4
20
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) 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 base
cover, then disconnect the water tank
end of the pump tubing to drain the water
tank. See Fig. 5. After the water tank has
drained, reconnect the pump tubing.
4) Remove the top and right side panels.
Disconnect This
End of Pump
Tubing to Drain
Water Tank
Base Cover
Fig. 5
5) Disconnect the 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 right side and top panels
and the base cover in their correct positions.
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 top and right side panels.
12) Disconnect FS connector from CB K5 connector.
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.
14) Replace cube guide and base cover (if applicable) in their correct positions.
15) Replace the right side and top panels in their correct positions.
16) Move the control switch to the "ICE" position, then replace the front panel in its correct
position. Turn on the power supply to start the automatic icemaking process.
Legend: CB–control board; FS–float switch
21
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) Remove the base cover, disconnect the water tank end of the pump tubing to drain the
water tank. See Fig. 5. After the water tank has drained, reconnect the pump tubing.
4) Remove the cube guide, then pull the tab on the float switch bracket to release the float
switch assembly from the water tank.
5) Remove the spring retainer clip from the float switch rod, then remove the float.
Be careful not to bend the spring retainer clip excessively when removing it. See Fig. 6.
6) Wipe down the float switch bracket assembly, stem, and float with a mixture of 1 part
Hoshizaki "Scale Away" and 25 parts warm water. Rinse the parts thoroughly with clean
water. WARNING! Do not remove the lock nut on the float switch assembly. This is
factory sealed and must not be removed.
7) Reassemble the float switch assembly and replace it in its correct position.
8) Move the control switch to the "ICE" position.
9) Replace the base cover, cube guide, and front panel in their correct positions.
10) Turn on the power supply to start the automatic icemaking process.
Legend: CB–control board; FS–float switch
Float Switch
Bracket Assembly
Water
Sealed
Connections
Float Switch
Bracket Assembly
Float Switch
Stem
Float Switch
Stem
Spring Retainer
Clip
Float
Float
Spring Retainer
Clip
Float Switch Tab
Water
Sealed
Connections
Fig. 6
22
Float Switch Tab
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, then remove the
top and right side panels.
3) Remove the thermistor from the refrigerant tubing.
4) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min.
5) 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.
6) Replace the thermistor in its correct position. See "IV.B. Component Service
Information."
7) Reconnect the thermistor connector to CB K3 connector.
8) Replace the right side and top panels in their correct positions.
9) Move the control switch to the "ICE" position.
10) Replace the front panel in its correct position.
11) Turn on the power supply.
12) Once the harvest cycle starts (Comp energizes), begin timing the harvest cycle.
13) 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 two positions: "ON for power on, "PUMP" to energize the pump
motor and circulate the water in the water tank.
H. Mode Switch
The mode switch has two positions: "ICE" for icemaking cycle, "CLEAN" for initiating the
cleaning and sanitizing program.
23
I. 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. Fuse (Control Box or Power
Supply Cord)
a) Blown.
3. Control Switch
a) In "OFF" or "PUMP" position.
b) Defective.
4. Main Transformer
a) Defective.
5. High-Pressure Switch
a) Dirty condenser.
b) Fan motor not operating.
c) Refrigerant overcharged.
d) Bad contacts.
e) Refrigerant lines or components plugged.
6. Control Transformer
(115VAC/10.5VAC)
a) Coil winding open or shorted.
7. Control Board
See "II.C. Control Board Check"
a) In alarm.
b) CB yellow "BC OPEN" LED on (bin full).
c) Defective.
8. Bin Control
See "II.D.1. Bin Control Check"
a) Tripped with bin filled with ice.
b) Sensor lens dirty.
c) Defective.
9. Mode Switch
a) In "CLEAN" position.
b) Defective.
10. Water Supply
a) Water supply off or improper water pressure.
b) External water filters clogged.
11. Inlet Water Valve
a) Screen or orifice clogged.
b) Coil winding open.
c) Water valve open in freeze cycle.
12. Float Switch
See "II.E. Float Switch Check
and Cleaning"
a) Float does not move freely.
13. Compressor
a) Compressor relay/magnetic contactor contacts bad or coil winding
open.
b) Defective.
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.
14. Hot Gas Valve
a) Closed in harvest cycle.
b) Open in freeze cycle.
15. Thermistor
See "II.F. Thermistor Check"
a) Loose, disconnected, or defective.
24
No Ice Production - Possible Cause
16. Pump Motor
a) Motor winding open.
b) Bearing worn out or locked rotor.
c) Defective capacitor.
d) Mechanical seal worn out.
17. Thermostatic Expansion Valve
a) Bulb loose.
b) Operating erratically.
18. Liquid Line Valve
a) Closed in freeze cycle.
b) Open in harvest cycle.
19. Fan Motor
a) Motor winding open.
b) Bearing worn out or locked rotor.
c) Defective capacitor.
20. Water System
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.J. 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 (S4 dip switch 1 & 2) set too short.
b) Defective.
b) Harvest pump timer (S4 dip switch 7) not in factory default position.
c) Defective.
9. Bin Control
See "II.D.1. Bin Control Check"
a) Defective.
25
Freeze-Up - Possible Cause
10. Thermistor
See "II.F. Thermistor Check"
a) Loose, disconnected, or defective.
11. Thermostatic Expansion Valve
a) Defective.
12. Hot Gas Valve
a) Defective.
13. Liquid Line Valve
a) Defective.
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 (S4 dip switch 9 & 10) set incorrectly.
5. Inlet Water Valve
a) Leaking by.
6. Float Switch
See "II.E. Float Switch Check
and Cleaning"
a) Float does not move freely.
7. Pump Motor
a) RPM too slow.
b) Out of position.
b) Defective.
b) Defective.
b) Impeller damaged.
8. Thermostatic Expansion Valve
a) Bulb loose or defective.
9. Liquid Line Valve
a) Restricted.
3. Low Ice Production
Low Ice Production - Possible Cause
Long Harvest Cycle
1. Evaporator
a) Scaled up.
2. Spray Tubes and/or Spray
Guides
a) Dirty.
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.
b) Defective.
26
Low Ice Production - Possible Cause
9. Compressor
a) Inefficient or off.
10. Liquid Line Valve
a) Erratic or open.
11. Thermostatic Expansion Valve
a) Defective.
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).
7. Refrigerant Charge
a) Low.
8. Thermostatic Expansion Valve
a) Bulb loose.
b) Float sticking.
c) Defective switch.
b) Defective.
b) Defective.
9. Compressor
a) Inefficient or off.
10. Pump Motor
a) RPM too slow.
11. Liquid Line Valve
a) Erratic or restricted.
12. Splash Guard
a) Out of place.
b) Missing or damaged.
27
J. 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 Sequence of 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?
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
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
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 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 splash guards in place?
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
[ ]
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
deenergized?
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) When activating bin control, did appliance
shutdown within 15 seconds in the first 5 minutes
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
28
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, bin
control, and float switch.
• Do not short out power supply to test for voltage.
• Always replace the whole control board assembly if it goes bad.
29
A. Control Board Layout
1. "K" Control Board
"K" Control Board
• "ALARM RESET"
Button
• S4 Dip Switch
• "OUTPUT TEST" Button
(used to test relays on control board)
• Bin Control Switch
Open LED (yellow)
• K3 (white) Connector
Thermistor
(harvest control and
high temperature safety)
• K9 (white)
(Cleaning and
Sanitizing Circuit)
• K4 (red) Connector
Bin Control
• Ext. Harvest LED
(yellow) (lights
when water line
thermistor initiates
extended harvest)
Not used this model
• S5 Dip Switch
• K5 (black) Connector
Float Switch
• Alarm Buzzer
• Part Number
• POWER OK LED
(red) (lights when
10.5VAC is supplied
to K2 connector)
• K1 Connector
Pins #1 through #10
#1 Hot Gas Valve (#2) and
Fan Motor/Liquid Line
Valve (#3) Power Supply
#2 Hot Gas Valve
#3 Fan Motor
Liquid Line Valve
#4 Pump Motor
#5 Drain Valve
#6 Inlet Water Valve
#7, 8 Open
#9 Compressor Relay,
Pin #1 Power Supply
(Hot Gas Valve (#2) and
Fan Motor/Liquid Line
Valve (#3))
#10 Component Power Supply
• 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 #3
• LED 3 (X3 Relay)
LED 3 on:
K1 Connector Pin #4
• LED 5 (X5 Relay)
LED 5 on:
K1 Connector Pin #5
• LED 4 (X4 Relay)
K1 Connector Pin #6
• LED 1 (X1 Relay)
K1 Connector Pin #9
• K2 Connector
Control Transformer
(10.5VAC)
"K" Control Board
Part Number 2A8242-01
30
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 1 through 5 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, 5, 3, 2.
Sequence Step
LED
Energized
Components
Time LEDs are On
Min.
Max.
1-Minute Fill Cycle
Harvest Cycle
Harvest Pump Time
(harvest assist)
Freeze Cycle
4
1, 4
1, 3
WV
Comp, HGV, WV
Comp, HGV, PM
1 minute 20 minutes
0 seconds 50 seconds
1, 2, 3
Comp, FM, PM, LLV
5 minutes
Slush Control
1, 2
Comp, FM, LLV
Pump-Out Cycle
1, 4*, 5, 3 Comp, HGV, PM, WV*, DV
*pump-out timer setting
freeze timer
setting
PM off 10 sec. when
thermistor at 36°F (2°C)
10 seconds 20 seconds
Alarms
Type
1
Beep
2
Beep
Alarm
Notes
High Evaporator Temp.
Check for harvest problem (stuck HGV or relay),
(temperature > 127°F) (53°C) hot water entering unit, or shorted thermistor.
Harvest Backup Timer
Check thermistor (open), HGV not opening, TXV or LLV
(harvest > 20 min. for two
leaking by, low charge, inefficient Comp.
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, LLV not opening, low
for two cycles in a row)
charge, or 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; LLV–liquid line valve; PM–pump motor; TXV–thermostatic expansion valve;
WV–inlet water valve
31
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.
1
2
3
4
5
6
7
8
9
10
KM-520MAJ
ON
ON OFF OFF ON OFF ON OFF ON
ON
KM-660MAJ
OFF OFF OFF OFF OFF OFF ON OFF ON
ON
S5 Dip Switch (Do Not Adjust)
1
2
3
4
5
OFF OFF OFF OFF ON
S4 Dip Switch
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 Time (1 & 2)
1 2 3 4 5
S5 Dip Switch
(Do Not Adjust)
ON
1 2 3 4 5 6 7 8 9 10
All Models
ON
Dip Switch No.
Slush Control (5)
Minimum Harvest Time (4)
Refill Counter (2 and 3)
Float Switch Selector (1)
32
2. Harvest Time (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. 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.
Time
(sec.)
S4 Dip Switch Setting
No. 1
No. 2
S5-4 OFF
S5-4 ON
OFF
OFF
60
30
ON
OFF
90
45
OFF
ON
120
60
ON
ON
180
75
3. Pump-Out Time/Harvest Time During Pump-Out (S4 dip switch 3 & 4)
When a pump-out is called for, the pump motor stops for 2 sec. After 2 sec. the drain
valve and pump motor energize. Water is removed from the bottom of the water tank
and sent down the drain. The pump‑out drains the water tank for the time determined by
the pump‑out timer. The pump‑out timer also acts in place of the harvest timer during
cycles with a pump‑out. The pump-out timer is factory set, and generally no adjustment
is required. However, where water quality is bad and the icemaker needs a longer
pump‑out time, the pump‑out timer can be adjusted. The pump‑out timer control can be
set to pump-out for 10 or 20 sec. During pump-out cycles minimum harvest time is based
on times given in the
table below.
S4 Dip Switch Setting
Time (sec.)
T1
No. 3
No. 4
OFF
OFF
ON
Inlet Water
Valve
T2
S5-4 OFF
S5-4 ON
S5-4 OFF
S5-4 ON
10
150
100
Closed
Closed
OFF
10
180
130
Closed
Closed
OFF
ON
10
120
70
Open
Closed
ON
ON
20
180
180
Closed
Closed
T1: Time to drain the water tank
T2: Harvest timer at pump out
33
4. Pump-Out Frequency Control (S4 dip switch 5)
The pump-out frequency control is factory set to drain the water tank every 10 cycles.
Generally no adjustment is required. However, where water quality is bad and the
icemaker needs a pump-out more often, the pump‑out frequency can be adjusted. The
pump-out frequency control can be set to have a pump‑out occur every cycle, or every
10 cycles.
The first pump-out is dependent on S4 dip switch 5. See the table below.
S4 Dip Switch Setting
Pump-Out Frequency
1st Pump-Out
OFF
Every 10 cycles
After 11th freeze cycle
ON
Every cycle
After 2nd freeze cycle
No. 5
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)
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
Harvest Pump Time
(Harvest Assist Duration)
No. 6
S5-4 OFF
S5-4 ON
OFF
50 sec.
25 sec.
ON
25 sec.
15 sec.
34
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, 50 sec. before harvest
termination, LED 4 turns off, inlet water valve Next, LED 3 turns on and control board
K1 connector pin #4 (R) 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
No. 7
Harvest Pump
Time (sec.)
(Harvest Assist)
OFF
0
ON
50
7. Factory Use (S4 dip switch 8)
Factory set for proper operation. Do not adjust. This must be left in the factory default
position.
35
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.I.3. Low Ice Production"
for possible solutions. The freeze timer is factory set and no adjustment is required.
Before changing this setting, contact Hoshizaki Technical Support at 1‑800‑233-1940 for
recommendations.
S4 Dip Switch Setting
No. 9
No. 10
Time
(min.)
OFF
OFF
60
OFF
ON
50
ON
OFF
70
ON
ON
75
9. Pump-Out Pump Motor Direction (S5 dip switch 1)
NOTICE
Do not adjust. This must be left in the factory default position or the icemaker will
not operate correctly.
The pump-out pump motor direction setting determines pump motor rotation during
pump-out.
On models with a drain valve pump motor rotation doesn't change at pump-out.
Pump motor rotates in forward direction and drain valve is energized for pump-out.
On models with a check valve, pump motor rotation reverses at pump-out.
Pump motor rotates in reverse direction and opens check valve for pump-out.
S5 Dip Switch Setting
No. 1
Pump-Out Components
OFF
Pump Motor Forward Rotation and Drain Valve
ON
Pump Motor Reverse Rotation and Check Valve
36
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
Refill
Counter
OFF
OFF
0
OFF
ON
1 refill
ON
OFF
9 refills
ON
ON
10 refills
11. Minimum Harvest Time (S5 dip switch 4)
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside the factory
default setting may result in damage to the appliance.
S5 Dip Switch Setting
No. 4
Minimum
Harvest Timer
OFF
120 sec.
ON
70 sec.
12. Slush Control (S5 dip switch 5)
This dip switch setting provides slush control during the freeze cycle. When the
evaporator temperature reaches 36°F (2.2°C) the control board reads a 5.8 kΩ signal
from the thermistor and de-energizes the water pump for 10 sec. to melt the ice slush
and prevent the ice slush from blocking the water supply tubing, causing irregular freeze
patterns.
NOTICE
Factory set for proper operation. Do not adjust. Adjustment outside the factory
default setting may result in damage to the appliance.
S5 Dip Switch Setting
No. 5
Slush
Control
OFF
Disabled
ON
Enabled
37
IV. Refrigeration Circuit and Component Service Information
WARNING
• This appliance should be diagnosed and repaired only by qualified service
personnel to reduce the risk of death, electric shock, serious injury, or fire.
• Move the control switch to the "OFF" position and turn off the power supply. Place
the disconnect in the "OFF" position. Lockout/Tagout to prevent the power supply
from being turned back on inadvertently.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are
securely in place after the icemaker is serviced. Make sure that none have fallen
into the dispenser unit/ice storage bin.
• Make sure all food zones in the icemaker and dispenser unit/ice storage bin are
clean after service.
A. Refrigeration Circuit Service Information
WARNING
• Repairs requiring the refrigeration circuit to be opened must be performed by
properly trained and EPA-certified service personnel.
• Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). Do not use R‑404A as a mixture with
pressurized air for leak testing.
NOTICE
• Always recover the refrigerant and store it in an approved container. Do not
discharge the refrigerant into the atmosphere.
• Do not leave the system open for longer than 15 min. when replacing or servicing
parts. The Polyol Ester (POE) oils used in R-404A applications can absorb
moisture quickly. Therefore it is important to prevent moisture from entering the
system when replacing or servicing parts.
• Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repair or replacement has been made.
Install the new drier with the arrow on the drier in the direction of the refrigerant
flow.
• When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
1. Refrigerant Recovery
The icemaker is provided with refrigerant access valves. Using proper refrigerant practices,
recover the refrigerant. Store the refrigerant in an approved container. Do not discharge the
refrigerant into the atmosphere.
38
2. Brazing
WARNING
• R-404A itself is not flammable at atmospheric pressure and temperatures up to
176°F (80°C).
• R-404A itself is not explosive or poisonous. However, when exposed to high
temperatures (open flames), R-404A can be decomposed to form hydrofluoric
acid and carbonyl fluoride both of which are hazardous.
• Do not use silver alloy or copper alloy containing arsenic.
1) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
Note: Because the pipes in the evaporator case are specially coated to resist corrosion,
it is important to make connections outside the evaporator case when possible.
If it is necessary to braze inside the evaporator case, use sandpaper to remove
the coating from the brazing connections before unbrazing the components.
NOTICE
• Always install a new drier every time the sealed refrigeration system is opened.
• Do not replace the drier until after all other repair or replacement has been made.
Install the new drier with the arrow on the drier in the direction of the refrigerant
flow.
• When brazing, protect the drier by using a wet cloth to prevent the drier from
overheating. Do not allow the drier to exceed 250°F (121°C).
2) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of
refrigerant to the system (if using an electronic leak detector), and then raise the
pressure using nitrogen gas (140 PSIG). Do not use R-404A as a mixture with
pressurized air for leak testing.
3. Evacuation and Recharge (R-404A)
1) Attach a vacuum pump to the system. Be sure to connect the charging hoses to both
high and low-side refrigerant access valves.
IMPORTANT
The vacuum level and vacuum pump may be the same as those for current
refrigerants. However, the rubber hose and gauge manifold to be used for
evacuation and refrigerant charge should be exclusively for POE oils.
2) Turn on the vacuum pump. Open the gauge manifold valves. Never allow the oil in the
vacuum pump to flow backwards.
3) Allow the vacuum pump to pull down to a 29.9" Hg vacuum. Evacuating period depends
on pump capacity.
4) Close the low-side valve and high-side valve on the gauge manifold.
39
5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a
refrigerant service cylinder. Remember to loosen the connection and purge the air from
the hose. For the required refrigerant charge, see the rating label inside the icemaker.
Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets
ARI Standard 700 (latest edition) be used.
6) A liquid charge is required when charging an R-404A system (to prevent fractionation).
Place the service cylinder on the scales; if the service cylinder is not equipped with
a dip tube, invert the service cylinder, then place it on the scales. Open the high-side
valve on the gauge manifold.
7) Allow the system to charge with liquid until the proper charge weight is met.
8) If necessary, add any remaining charge to the system through the low-side.
NOTICE! To prevent compressor damage, use a throttling valve or liquid
dispensing device to add the remaining liquid charge through the low-side
refrigerant access valve with the icemaker running.
9) Close the high and low-side gauge manifold valves, then disconnect the gauge manifold
hoses.
10) Cap the refrigerant access valves to prevent a possible leak.
40
B. Component Service Information
NOTICE
When replacing a component listed below, see the notes to help ensure proper
operation.
Component
Compressor
Notes
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
Liquid Line
Valves
• Replace the strainer if applicable.
• Use copper tube of the same diameter and length when replacing valve lines.
Fan Motors
Install a new capacitor.
Pump Motor
Install a new capacitor.
Thermistor
• Attach the new thermistor to the suction line in the same location as the previous
thermistor.
• The thermistor should be at the 12 o'clock position on the tube.
• Smoothly fill the recessed area of the thermistor holder with high thermal conductive
type sealant. Hoshizaki America part number 4A0683-01 (Silicone Heat Sink Compound
10-8108 manufactured by GC Electronics), KE-4560 RTV (manufactured by ShinEtsu
Silicones), or equivalent are recommended.
• Secure the thermistor with the holder, then insulate it.
• Be very careful to prevent damage to the leads.
41
V. Maintenance
The maintenance schedule below is a guideline. More frequent maintenance may be
required depending on water quality, the appliance's environment, and local sanitation
regulations
WARNING
• Only qualified service technicians should service the appliance.
• To reduce the risk of electric shock, do not touch the control switch or service
switch with damp hands
• Before servicing: Move the control switch to the "OFF" position and turn off the
power supply. Place the disconnect in the "OFF" position.
Lockout/Tagout to prevent the power supply from being turned back on
inadvertently.
• CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are
securely in place after any maintenance is done to the icemaker. Make sure that
none have fallen into the dispenser unit/ice storage bin.
Maintenance Schedule
Frequency Area
Task
Daily
Scoop
Bi-Weekly
Monthly
Clean the ice scoop using a neutral cleaner. Rinse thoroughly after
cleaning.
Inspect. Wash with warm water and neutral cleaner if dirty.
Check for proper pressure and change if necessary.
Air Filters
External Water
Filters
Icemaker Exterior Wipe down with a clean, soft cloth. Use a damp cloth containing a
neutral cleaner to wipe off oil or dirt build up. Clean any chlorine staining
(rust colored spots) using a non-abrasive cleanser.
Underside of
Wipe down with a clean cloth and warm water.
Icemaker and Top
Kits; Bin Door and
Snout
Icemaker and
Clean and sanitize per the cleaning and sanitizing instructions provided
Dispenser Unit/Ice in the instruction manual or maintenance label on the icemaker.
Storage Bin Liner
Water Supply Inlet Close the icemaker water supply line shut‑off valve and drain the water
system. Clean the water supply inlet screen.
Condenser
Inspect. Clean if necessary by using a brush or vacuum cleaner. More
frequent cleaning may be required depending on location.
Water Hoses
Inspect the water hoses and clean/replace if necessary.
Yearly
42
VI. Preparing the Appliance for Periods of Non-Use
NOTICE
• When storing the appliance for an extended time or in sub-freezing temperatures,
follow the instructions below to prevent damage.
• To prevent damage to the water pump, do not operate the appliance with the
control switch in the "WASH" position when the water tank is empty.
When the appliance is not used for two or three days under normal conditions, it is
sufficient to move the control switch to the "OFF" position. When storing the appliance for
an extended time or in sub-freezing temperatures, follow the instructions below.
1. Remove the water from the icemaker water line:
1) Turn off the power supply, then remove the front panel.
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.
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 base
cover, then disconnect one end of the
pump tubing to drain the water tank.
See Fig. 8. After the water tank has drained,
reconnect the pump tubing.
4) Replace the base cover (if applicable) and
front panel in their correct positions.
Disconnect This
End of Pump
Tubing to Drain
Water Tank
Base Cover
Fig. 8
5) Remove all ice from the dispensing unit/ice storage bin. Clean the storage bin liner
using a neutral cleaner. Rinse thoroughly after cleaning.
43
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.
44
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-520MAJ-E
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.)
APPROXIMATE ICE PRODUCTION
PER 24 HR. FOR EUROPE MARKET
lbs./day (kg/day)
SHAPE OF ICE
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
230/1/50
8.4 A (5 Min. Freeze AT 104°F/WT 80°F)
15 A
15 A
90/70°F
70/50°F
1180 (6.52)
1070 (4.88)
124 (28.5)
211 (40.1)
10/10°C
20/15°C
*555 (252)
*515 (234)
Crescent Cube
10.9 lbs. (4.9 kg) 480pcs.
Ultra-Sonic Sensor
R404A, 1 lb. 1.7 oz. (500g)
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
525
505
498
484
211
191
185
153
215
230
234
242
40
42
43
44
30/25°C
*424 (192)
50/10
1070
1095
1102
1024
22
23
23
24
3.4
3.0
3.0
2.5
WATER TEMP. (ºF/ºC)
70/21
90/32
238
498
226
449
204
229
463
210
407
185
226
434
197
380
172
220
421
191
330
150
1102
985
1145
937
1180
1008
1140
850
0.80
185
0.70
165
0.63
0.72
152
0.57
140
0.53
0.70
124
0.47
108
0.41
0.58
120
0.46
94
0.36
23
26
25
28
26
29
27
32
3.0
2.8
2.4
2.5
2.0
2.0
2.0
2.0
15.1
234
16.5
266
18.7
16.1
259
18.2
294
20.6
16.5
280
19.7
314
22.1
17.0
288
20.2
345
24.3
2.8
43
3.0
48
3.4
3.0
47
3.3
52
3.7
3.0
50
3.5
55
3.9
3.1
51
3.6
60
4.2
7,300 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
45
ENG.F-011.1.0205
2. KM-660MAJ-E
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.)
APPROXIMATE ICE PRODUCTION
PER 24 HR.FOR EUROPE MARKET
lbs./day (kg/day)
SHAPE OF ICE
ICE PRODUCTION PER CYCLE
BIN CONTROL SYSTEM
REFRIGERANT CHARGE
Performance Data Sheet
APPROXIMATE ICE PRODUCTION
PER 24 HR.
230/1/50
8.4 A (5 Min. Freeze AT 104°F/WT 80°F)
15 A
15 A
90/70°F
70/50°F
1170 (4.85)
1080 (4.18)
79 (13.7)
161 (26.1)
10/10°C
20/15°C
*648 (294)
*608 (276)
Crescent Cube
10.9 lbs. (4.9 kg) 480pcs.
Ultra-Sonic Sensor
R404A, 1 lb. 10.9 oz. (760g)
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
618
609
606
590
161
143
137
109
215
230
234
242
40
42
43
44
30/25°C
*568 (258)
50/10
1080
1100
1106
1113
22
23
23
24
3.4
3.0
3.0
2.5
WATER TEMP. (ºF/ºC)
70/21
90/32
280
606
275
565
276
591
268
536
275
578
262
528
267
566
257
482
1106
1142
1141
1177
1170
1206
1179
1240
0.61
137
0.52
124
0.54
106
0.40
104
0.52
79
0.30
72
0.41
77
0.29
66
23
26
25
28
26
29
27
32
3.0
2.8
2.4
2.5
2.0
2.0
2.0
2.0
15.1
234
16.5
266
16.1
259
18.2
294
16.5
280
19.7
314
17.0
288
20.2
345
2.8
43
3.0
48
3.0
47
3.3
52
3.0
50
3.5
55
3.1
51
3.6
60
7,300 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
1,400 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
256
243
240
219
0.47
0.39
0.27
0.25
18.7
20.6
22.1
24.3
3.4
3.7
3.9
4.2
ENG.F-011.1.0205
46
*
47
412±22
0 PSIG
327±22 PSIG
Cut-out
Cut-in
Air Models
* High-Pressure Switch
B. Wiring Diagrams
1. KM-520MAJ-E, KM-660MAJ-E