Hoshizaki American, Inc. KM-255BAH Service manual

Hoshizaki
Hoshizaki America, Inc.
Self-Contained Crescent Cuber
Models
KM-255BAH
KM-255BWH
“A Superior Degree
of Reliability”
SERVICE MANUAL
www.hoshizaki.com
®
Number: 73146
Issued: 1-2-2007
IMPORTANT
Only qualified service technicians should attempt to install, service or maintain
this icemaker. No installation, service or maintenance should be undertaken
until the technician has thoroughly read this Service Manual.
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, write or send an e-mail message to the HOSHIZAKI Technical
Support Department.
HOSHIZAKI AMERICA, INC.
618 Highway 74 South
Peachtree City, GA 30269
Attn: HOSHIZAKI Technical Support Department
Phone: 1-800-233-1940 Technical Service
(770) 487-2331
Fax: 1-800-843-1056
(770) 487-3360
E-mail: [email protected]
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
Please review this manual. It should be read carefully before the icemaker is serviced or
maintenance operations are performed. Only qualified service technicians should service
and maintain the icemaker. This manual should be made available to the technician prior to
service or maintenance.
CONTENTS
I. Specifications....................................................................................................................... 5
A. Icemaker........................................................................................................................ 5
1. KM-255BAH (air-cooled).......................................................................................... 5
2. KM-255BWH (water-cooled)..................................................................................... 6
II. General Information............................................................................................................ 7
A. Construction................................................................................................................... 7
1. KM-255BAH (air-cooled).......................................................................................... 7
2. KM-255BWH (water-cooled)..................................................................................... 8
B. Sequence of Operation.................................................................................................. 9
1. One Minute Fill Cycle............................................................................................... 9
2. Initial Harvest Cycle . ............................................................................................... 9
3. Freeze Cycle ........................................................................................................... 9
4. Normal Harvest Cycle ............................................................................................. 9
C. Control Board............................................................................................................... 12
1. Control Board Layout.............................................................................................. 13
2. Features................................................................................................................. 14
a) Maximum Water Supply Period – 6 minutes........................................................ 14
b) Harvest Backup Timer and Freeze Timer............................................................ 14
c) High Temperature Safety..................................................................................... 14
d) Low Water Safety................................................................................................ 14
e) High Voltage and Low Voltage Cut-outs.............................................................. 14
f) LED Lights and Audible Alarm Safeties................................................................ 15
3. Controls and Adjustments...................................................................................... 16
a) Default Dip Switch Settings................................................................................. 16
b) Harvest Control – Thermistor.............................................................................. 16
c) Harvest Timer (S4 dip switch 1 & 2).................................................................... 17
d) S4 dip switch 3, 4, 5, 6, 7, & 8............................................................................. 17
e) Freeze Timer (S4 dip switch 9 & 10)................................................................... 17
f) Float Switch Control and Refill Counter (S5 dip switch 1 through 5).................... 17
g) Bin Control........................................................................................................... 18
4. Bin Control Troubleshooting.................................................................................... 18
a) Machine Will Not Start......................................................................................... 18
b) Machine Will Not Shut Off................................................................................... 18
5. Float Switch Troubleshooting.................................................................................. 18
6. Control Board Check Procedure............................................................................. 19
7. Control Board Replacement................................................................................... 20
III. Technical Information....................................................................................................... 21
A. Water Circuit and Refrigeration Circuit......................................................................... 21
1. KM-255BAH (air-cooled)........................................................................................ 21
2. KM-255BWH (water-cooled)................................................................................... 22
B. Wiring Diagram............................................................................................................. 23
1. KM-255BAH (air-cooled)........................................................................................ 23
2. KM-255BWH (water-cooled)................................................................................... 24
C. Performance Data........................................................................................................ 25
1. KM-255BAH (air-cooled)........................................................................................ 25
2. KM-255BWH (water-cooled)................................................................................... 26
IV. Service Diagnosis............................................................................................................ 27
A. 10-Minute Diagnostic Procedure . ............................................................................... 27
B. Diagnostic Charts......................................................................................................... 28
1. No Ice Production................................................................................................... 28
2. Evaporator is Frozen Up......................................................................................... 32
3. Low Ice Production................................................................................................. 33
4. Abnormal Ice.......................................................................................................... 33
5. Other....................................................................................................................... 33
V. Removal and Replacement of Components..................................................................... 35
A. Servicing the Refrigeration Circuit............................................................................... 35
1. Refrigerant Recovery.............................................................................................. 35
2. Evacuation and Recharge (R-404A)....................................................................... 35
B. Brazing......................................................................................................................... 36
C. Removal and Replacement of Compressor................................................................. 36
D. Removal and Replacement of Drier............................................................................. 37
E. Removal and Replacement of Expansion Valve........................................................... 38
F. Removal and Replacement of Hot Gas Valve............................................................... 39
G. Removal and Replacement of Evaporator................................................................... 40
H. Removal and Replacement of Air-Cooled Condenser................................................. 40
I. Removal and Replacement of Water-Cooled Condenser.............................................. 41
J. Removal and Replacement of Water Regulating Valve - Water‑Cooled Model Only.... 42
K. Adjustment of Water Regulating Valve - Water-Cooled Model Only............................. 42
L. Removal and Replacement of Thermistor.................................................................... 43
M. Removal and Replacement of Fan Motor.................................................................... 44
N. Removal and Replacement of Freeze or Harvest Water Valve.................................... 44
O. Removal and Replacement of Wash Valve.................................................................. 45
P. Removal and Replacement of Pump Motor.................................................................. 45
Q. Removal and Replacement of Spray Tube................................................................... 46
VI. Cleaning and Maintenance Instructions.......................................................................... 47
A. Cleaning....................................................................................................................... 47
1. Cleaning Procedure................................................................................................ 47
2. Sanitizing Procedure - Following Cleaning Procedure........................................... 49
B. Maintenance................................................................................................................. 49
C. Preparing the Icemaker for Long Storage.................................................................... 50
I. Specifications
A. Icemaker
1. KM-255BAH (air-cooled)
AC SUPPLY VOLTAGE
AMPERAGE
MINIMUM CIRCUIT AMPACITY
MAXIMUM FUSE SIZE
APPROXIMATE ICE PRODUCTION
PER 24 HR.
lbs./day ( kg/day )
Reference without *marks
SHAPE OF ICE
ICE PRODUCTION PER CYCLE
APPROXIMATE STORAGE CAPACITY
ELECTRIC & WATER CONSUMPTION
ELECTRIC W (kWH/100 lbs.)
WATER gal./24HR (gal./100 lbs.)
EXTERIOR DIMENSIONS (WxDxH)
EXTERIOR FINISH
WEIGHT
CONNECTIONS - ELECTRIC
- WATER SUPPLY
- DRAIN
CUBE CONTROL SYSTEM
HARVESTING CONTROL SYSTEM
ICE MAKING WATER CONTROL
COOLING WATER CONTROL
BIN CONTROL SYSTEM
COMPRESSOR
CONDENSER
EVAPORATOR
REFRIGERANT CONTROL
REFRIGERANT CHARGE
DESIGN PRESSURE
P.C. BOARD CIRCUIT PROTECTION
COMPRESSOR PROTECTION
REFRIGERANT CIRCUIT PROTECTION
LOW WATER PROTECTION
ACCESSORIES -SUPPLIED
-REQUIRED
OPERATING CONDITIONS
115/60/1
9 A ( 5 Min. Freeze AT 104°F / WT 80°F)
N/A
N/A
Ambient
WATER TEMP. (°F)
Temp.(°F)
50
70
90
70
* 235 (107)
227 (103)
207 (94)
80
229 (104)
216 (98)
191 (87)
90
227 (103)
* 207 (94)
184 (83)
100
211 (96)
202 (91)
163 (74)
Crescent Cube
4 lbs. ( 1.8 kg ) 204 pcs.
120 lbs.
90/70°F
70/50°F
828 (9.6)
744 (7.6)
51 (24.7)
82 (35.0)
30" x 28" x 39" (762 x 711 x 990 mm)
Includes 6" leg
Stainless steel; Galvanized steel (rear)
Net 203 lbs. ( 92 kg ), Shipping 220 lbs. ( 100 kg )
Cord Connection
Inlet
1/2" FPT
Outlet 3/4" FPT
N/A (Internal programming)
Hot Gas and Water, Thermistor and Timer
Timer Controlled. Overflow Pipe
N/A
Mechanical Level Switch and Timer
Hermetic, Model SC12MLX
Air cooled, Fin and Tube type
Vertical type, Stainless Steel and Copper
Thermostatic Expansion Valve
R-404A,
1 lb. 1 oz. (475 g)
High 467 PSIG, Low 240 PSIG
High Voltage Cut-out ( Internal )
Auto-reset Overload Protector ( Internal )
Auto-reset High Pressure Control Switch
Float Switch
Ice Scoop; 6" Leg, 4 pcs.
N/A
VOLTAGE RANGE
104 - 127 V
AMBIENT TEMP.
45 - 100° F
WATER SUPPLY TEMP.
45 - 90° F
WATER SUPPLY PRESSURE
10 - 113 PSIG
Note: We reserve the right to make changes in specifications and design without prior
notice.
2. KM-255BWH (water-cooled)
Intentionally Left Blank
Note: We reserve the right to make changes in specifications and design without prior
notice.
II. General Information
A. Construction
1. KM-255BAH (air-cooled)
Harvest
Water
Valve
Rear View of Icemaker
Expansion
Valve
Freeze
Water
Valve
Wash Valve
Evaporator
Drier
Spray Tube
Water Tank, Bin Control & Pump Motor
Bin Control Switch
(back side of tank)
Bin Control
Detector
Control Box
Water Tank
Condenser
Float
Switch
Pump
Motor
Fuse
Rear View of Compressor & Condenser
Electrical
Box
Control Switch Compressor
Fan Motor
Hot Gas
Valve
Strainer
2. KM-255BWH (water-cooled)
Harvest
Water
Valve
Rear View of Icemaker
Expansion
Valve
Freeze
Water
Valve
Wash Valve
Evaporator
Drier
Spray Tube
Water Tank, Bin Control & Pump Motor
Bin Control
Detector
Bin Control Switch
(back side of tank)
Control Box
Water Tank
Condenser
Float
Switch
Fuse
Pump
Motor
Rear View of Compressor & Condenser
Electrical
Box
Water
Regulator
Control Switch Compressor
Strainer
Hot Gas
Valve
B. Sequence of Operation
The steps in the sequence are as outlined below. When power is supplied, the red LED
on the control board comes on. A 5 second delay occurs at startup. Note that the order
of the green LEDs from the outer edge of the board is 1, 4, 3, 2.
1. One Minute Fill Cycle
LED 4 is on. FWV opens and the fill period begins. After 1 minute, the board checks
for a closed LF/S. If LF/S is closed, the harvest cycle begins. If not, FWV will remain
energized through additional 1 minute cycles until water enters the sump and LF/S
closes. This serves as a low water safety to protect the water pump.
2. Initial Harvest Cycle
LEDs 1, 4 and 2 are on. FWV closes, HGV opens, water valve relay energizes and HWV
opens, Comp energizes, and harvest begins. The control board monitors the warming
of the evaporator via the thermistor located on the suction line. When the thermistor
reaches 48°F (9°C), the control board reads a 3.9 kΩ signal from the thermistor and
turns harvest termination over to the adjustable harvest timer which is factory set for
normal conditions. The timer has settings of 60, 90, 120, and 180 seconds (S4 dip switch
1 & 2). When the harvest timer completes its count down, the harvest cycle is complete
and the freeze cycle starts. The minimum total time allowed by the board for a complete
harvest cycle is 2 minutes. HWV is open during harvest for a maximum of 6 minutes or
the length of harvest minus 50 seconds, whichever is shorter. PM energizes and runs
for the last 50 seconds of harvest. At the end of harvest, the control board checks the
position of LF/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute fill
if it is open.
3. Freeze Cycle
LED 1 is on. Comp and PM continue to run, FMS energizes, HGV closes, water valve
relay de-energizes and HWV closes, and the freeze cycle starts. For the first 5 minutes
the control board will not accept a signal from LF/S. This 5 minute minimum freeze acts
as a short cycle protection. At the end of 5 minutes, LF/S assumes control. As ice builds
on the evaporator, the water level in the sump lowers and UF/S opens. 15 seconds after
UF/S opens, FWV opens (LED 4 is on when FWV is open) and allows water in. After
UF/S closes again, FWV closes 3 seconds later. This continues until the tank has refilled
the number of times determined by the refill counter (S5 dip switch is factory set - do not
adjust). The KM-255BAH and KM-255BWH refill 10 times. After the final refill, the freeze
continues until LF/S opens and terminates the freeze cycle.
Note: After the first freeze following startup and every 10th cycle thereafter, LEDs 1, 3,
and 2 come on between freeze and harvest. Comp continues to run, HGV opens
and FMS de-energizes. PM stops for 2 seconds. PM restarts and runs for 10
seconds.
4. Normal Harvest Cycle
LEDs 1, 4 and 2 are on. Comp continues to run, HGV opens, water valve relay energizes
and HWV opens. As the evaporator warms, the thermistor reaches 48°F (9°C). The
control board then receives the thermistor's 3.9 kΩ signal and starts the harvest timer.
When the harvest timer completes its count down, the harvest cycle is complete and
the next freeze cycle starts. The minimum total time allowed by the board for a complete
harvest cycle is 2 minutes. HWV is open during harvest for a maximum of 6 minutes or
the length of harvest minus 50 seconds, whichever is shorter. PM energizes and runs
for the last 50 seconds of harvest. At the end of harvest, the control board checks the
position of LF/S and proceeds to the freeze cycle if it is closed or calls for a 1-minute fill if
it is open.
The unit continues to cycle through freeze and harvest cycles until the bin control
activates and shuts the unit down.
Legend: Comp–compressor; FMS–self-contained fan motor; FWV–freeze water valve;
HGV–hot gas valve; HWV–harvest water valve; LF/S–lower float switch; PM–pump
motor; UF/S–upper float switch
10
11
LF/S closed
Thermistor in
control
Freeze cycle
operation turned
over to LF/S
Lower float
switch in
control
Comp continues
HGV energized
FMS de-energized
Pump motor stops
for 2 sec. and then
runs for 10 sec.
End of 1st
freeze and
every 10th
cycle thereafter
The WASH position on the control switch is used when cleaning and sanitizing the machine. When in
the WASH position, power is supplied to the pump motor and the wash valve. This allows cleaner and
sanitizer to flow over both the inside and outside of the evaporator plate assembly.
Comp continues
HGV de-energized
HWV de-energized
PM continues
FMS energized
FWV energized/
de-energized for refills only
LF/S closed
5 minute timer
in control
• Minimum freeze time: 5 minutes
• Maximum freeze time: freeze timer setting
• Upper float switch used to initiate and
complete water tank refills (10 refills for
KM‑255BAH and KM‑255BWH)
3. Freeze Cycle
Components Energized when the Control Switch is in the WASH Position
If LF/S is open, compressor stops and cycle returns to 1 minute fill
Thermistor temp
reaches 48°F (9°C)
(3.9 kΩ or less)
Harvest timer starts
LF/S open
LF/S Check
PM energized
50 sec.
1 to 3 minute timer
in control
• Maximum harvest water valve time: 6 minutes
(HWV time is 6 minutes or the length of
harvest minus 50 sec., whichever is shorter.
PM energizes and runs for the last 50 sec. of
harvest.)
• Maximum harvest time: 20 minutes
2. Harvest Cycle
Comp energized
HGV energized
LF/S open FWV de-energized
HWV energized
FWV Energized
LF/S Check
1. One Minute
Fill Cycle
Legend:
Comp - compressor
FMS - self-contained fan motor
FWV - freeze water valve
HGV - hot gas valve
HWV - harvest water valve
LF/S - lower float switch
PM - pump motor
UF/S - upper float switch
"G" board will have
5 second delay
Initial startup always
begins here
Cycle Steps
KM-255BAH and KM-255BWH Sequence Flow Chart and Component Operation
C. Control Board
• A HOSHIZAKI exclusive solid-state control is employed in KM-255BAH and
KM‑255BWH Self-Contained Crescent Cubers.
• All models are pretested and factory-adjusted.
CAUTION
1. Fragile, handle very carefully.
2. A 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 unit when handling or replacing the board.
3. Do not touch the electronic devices on the board or the back of the board to
prevent damage to the board.
4. Do not change wiring and connections. Do not misconnect K3, K4 and K5,
because the same connector is used for the thermistor, float switch and
mechanical bin control.
5. Always replace the whole board assembly if it goes bad.
6. Do not short out power supply to test for voltage.
12
1. Control Board Layout
Control Products "G" Control Board
Connector K2
Transformer
Switch for "C" board
and "ALPINE" board
(service boards only)
Relay LEDs (4)
(indicate which
relays are energized
as listed below)
LED 1 (green)
Compressor (Comp)
LED 4 (green)
Freeze Water Valve
(FWV) (when LED 2
is off)
Harvest Water Valve
(HWV) (when LED 2
is on)
Connector K1
Pins #1 through #10
#1, 9 Magnetic Contactor
#2 Hot Gas Valve (HGV)
Water Valve Relay (for harvest
water valve operation)
#3 Self-Contained Fan Motor (FMS)
#4 Pump Motor (icemaking)
#5 Pump Motor (harvest)
#6 Freeze Water Valve (FWV)
#7, 10 Supply Voltage
#8 Open
LED 3 (green)
Pump Motor (PM)
(PM on, but LED off,
at freeze cycle)
LED 2 (green)
Hot Gas Valve (HGV)
Harvest Water Valve
(HWV) (when LED 4
is on)
Self-Contained Fan
Motor (FMS) (FMS
off when LED on)
Label
(board revision level
indicated on label
on side of relay)
Connector K5
Float Switch
Power LED (red)
(lights when power
is supplied to the
board)
S5 Dip Switch
(factory set do not adjust)
Alarm Buzzer
Connector K4
Mechanical Bin
Control
Part Number
Bin Control Switch
Open LED (yellow)
Connector K3
Harvest Control
(thermistor)
Bin Control Switch
Closed LED (green)
Output Test Switch
(used to test relays on board)
S4 Dip
Switch
Control Board
Part Number 2A3792-01 (factory); 2A3792-02 (service)
13
Alarm Reset Switch
2. Features
a) Maximum Water Supply Period – 6 minutes
The harvest water valve will be open during harvest for 6 minutes or the length of harvest
minus 50 seconds, whichever is shorter.
b) Harvest Backup Timer and Freeze Timer
The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest
cycle takes more than 20 minutes to complete. The control board will signal this problem
using 2 beeps every 3 seconds.
The freeze timer shuts down the icemaker if, for two cycles in a row, the freeze cycle
takes longer than the time specified to complete. The control board will signal this
problem using 3 beeps every 3 seconds. The time is factory set using S4 dip switch 9 &
10.
The reset button on the control board must be pressed with power on to reset either of
these safeties.
c) High Temperature Safety
The temperature of the suction line in the refrigeration circuit is limited by the high
temperature safety. This protects the unit from excessively high temperatures. If the
evaporator temperature rises above 127 ± 7°F (53 ± 4°C), the control board reads a
.804 kΩ signal from the thermistor and operates the safety. This shuts down the circuit
and the icemaker automatically stops.
The control board will signal this problem using 1 beep every 3 seconds. The reset button
on the control board must be pressed with power on to reset the safety.
d) Low Water Safety
The control board checks the position of the lower float switch at the end of the initial one
minute water fill cycle and at the end of each harvest cycle. If the lower float switch is
closed, the control board proceeds to the next cycle. If the lower float switch is open, the
control board calls for a one minute water fill cycle. After one minute, the control board
checks the position of the float and either proceeds to the next cycle if the lower float
switch is closed or calls for an additional one minute fill if the switch is open. This serves
as a low water safety to protect the water pump.
For water-cooled model, if the water is shut off, the unit is also protected by the high
pressure switch.
e) High Voltage and Low Voltage Cut-outs
High voltage and low voltage cut-outs help protect the icemaker from supply voltages
outside of the accepted range.
If miswiring causes excessive voltage (147Vac ±5% or more for 3 seconds) on the
control board, the high voltage cut-out shuts down the circuit and the icemaker
automatically stops. The control board will signal this problem using 7 beeps every 3
seconds.
The icemaker also automatically stops in cases of insufficient voltage (92Vac ±5% or
less). The control board will signal this problem using 6 beeps every 3 seconds.
When the proper supply voltage is resumed, the icemaker automatically starts running
again.
14
f) LED Lights and Audible Alarm Safeties
The red LED indicates control voltage (10 to 12V at K2) and will remain on unless a
control voltage problem occurs. At startup a 5 second delay occurs while the board
conducts an internal timer check. A beep occurs when the control switch is moved to the
ICE position.
The green LEDs 1 through 4 energize and sequence from initial startup as listed in the
table below. Note that the order of the LEDs from the outer edge of the board is 1, 4, 3,
2. For more information, see "II.B. Sequence of Operation."
Time LEDs are On
Energized
Sequence Step
LED
Components
Min.
Max.
Avg.
1 Minute Fill Cycle 4
FWV
60 seconds
Harvest Cycle
1, 4 and 2
HWV, HGV, 2 minutes 20 minutes 3 to 5 minutes
Comp
Last 50 seconds of harvest, HWV de-energizes and PM energizes
(LEDs 1, 3 and 2 are on)
Freeze Cycle
1 (and 4 at Comp, PM, 5 minutes freeze timer 30 to 35 minutes
refills)
FMS (FWV
setting
at refills)
After the first freeze following startup and every 10th cycle thereafter, Comp, HGV, and PM
are energized for 10 seconds between freeze and harvest (LEDs 1, 3 and 2 are on)
The built in safeties shut down the unit and have alarms as listed below.
No. of Beeps
Type of Alarm
Notes
(every 3 sec.)
1
High Evaporator Temp.
Check for harvest problem (stuck HGV or
(temperature > 127°F)
relay), hot water entering unit, or shorted
(53°C)
thermistor.
2
Harvest Backup Timer
Check for open thermistor, HGV not
(harvest > 20 min. for two opening, TXV leaking by, low charge,
cycles in a row)
inefficient Comp, or WRV leaking by
(water-cooled model only).
3
Freeze Timer
Check for a float switch stuck closed (up),
(freeze > specified setting HWV or FWV leaking by, HGV leaking by,
for two cycles in a row)
TXV not feeding properly, low charge, or
Timer is factory set using inefficient compressor.
S4 dip switch 9 & 10
To manually reset the above safeties, press the alarm reset button with the power
supply on.
6
Low Voltage
Red LED will turn off if voltage protection
(92Vac ±5% or less)
operates.
The control voltage safeties automatically
7
High Voltage
reset when voltage is corrected.
(147Vac ±5% or more)
Legend: Comp–compressor; FMS–self-contained fan motor; FWV–freeze water valve;
HGV–hot gas valve; HWV–harvest water valve; PM–pump motor; TXV–
thermostatic expansion valve; WRV–water regulating valve
15
3. Controls and Adjustments
a) Default Dip Switch Settings
The dip switches are factory-adjusted to the following positions:
S4 Dip Switch
Dip Switch No.
1
2
3
4
5
6
7
8
9
10
KM-255BAH
OFF ON OFF ON
ON
ON
ON OFF OFF OFF
KM-255BWH
ON OFF OFF ON
ON
ON
ON OFF OFF OFF
S5 Dip Switch (Do Not Adjust)
Dip Switch No.
1
2
3
4
5
KM-255BAH
ON OFF ON OFF ON
KM-255BWH
ON OFF ON OFF ON
S5 (do not adjust)
S4
Freeze Timer (9 & 10)
Do not adjust (3, 4, 5, 6, 7, & 8)
Float switch
control and refill
counter. Do not
adjust.
Harvest Timer (1 & 2)
b) Harvest Control – Thermistor
A thermistor (semiconductor) is used for a harvest control sensor. The resistance varies
depending on the suction line temperatures. The thermistor detects the temperature of
the evaporator outlet to start the harvest timer. No adjustment is required. If necessary,
check for resistance between thermistor leads, and visually check the thermistor
mounting, located on the suction line next to the evaporator outlet.
Temperature (°F) Temperature (°C)
0
10
32
50
70
90
-18
-12
0
10
21
32
Resistance (kΩ)
14.401
10.613
6.000
3.871
2.474
1.633
Check a thermistor for resistance by using the following procedure:
1) Disconnect the connector K3 on the board.
2) Remove the thermistor. See "V.L. Removal and Replacement of Thermistor."
16
3) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3
minutes.
4) Verify the temperature of the glass, then check for resistance between thermistor leads.
See the table above for temperature and resistance values. Normal reading is within
3.5 to 7 kΩ. Replace the thermistor if it exceeds the normal reading.
c) Harvest Timer (S4 dip switch 1 & 2)
The harvest timer starts counting when the thermistor reads 48°F (9°C) at the
evaporator outlet.
No adjustment is required under normal use, as the harvest timer is adjusted to the
suitable position. Before changing this setting, call the HOSHIZAKI Technical Support
Department at 1‑800‑233‑1940 for recommendations. Keep in mind that setting the
harvest timer to a longer setting will decrease 24 hour production.
Dip Switch Setting
Time
No. 1
No. 2 (seconds)
OFF
OFF
60
ON
OFF
90
OFF
ON
120
ON
ON
180
d) S4 dip switch 3, 4, 5, 6, 7, & 8
Factory set for optimum performance. Do not adjust.
e) Freeze Timer (S4 dip switch 9 & 10)
CAUTION
Adjust to proper specification, or the unit may not operate correctly.
The freeze timer setting determines the maximum allowed freeze time to prevent
possible freeze-up issues. Upon termination of freeze timer, the control board initiates
the harvest cycle. After 2 consecutive timer terminations, the control board shuts the
machine down. In this case, see "IV.B.3. Low Ice Production" for possible solutions.
The freeze timer is factory adjusted and no adjustment is required.
Dip Switch Setting
No. 9
OFF
OFF
ON
ON
No. 10
OFF
ON
OFF
ON
Time
(minutes)
60
50
70
60
f) Float Switch Control and Refill Counter (S5 dip switch 1 through 5)
These must be left in the factory default position or the unit will not operate properly. Do
not adjust. The KM-255BAH and KM-255BWH refill 10 times.
Note: There are no refills during the first 5 minutes of the freeze cycle. The first refill
generally lasts about 10 seconds and subsequent refills generally last about
5 seconds.
17
g) Bin Control
This machine uses a lever-actuated proximity switch (mechanical bin control) to control
the ice level in the storage bin. No adjustment is required.
(1) Explanation of Operation
The bin control is connected to the K4 connector on the control board. When the bin
control is calling for ice (proximity switch closed; green LED, BC CLOSED, on), the
control board continues icemaking operations. When the bin control is activated in the
bin full position (proximity switch open; yellow LED, BC OPEN, on), the control board
shuts down the unit. However, to prevent incomplete batches of ice from forming on the
evaporator, the control board will only shut down the machine within the first 5 minutes of
the freeze cycle. If ice pushes the lever in after the first five minutes of the freeze cycle,
the control board will allow the machine to complete the freeze cycle and the following
harvest cycle before shutting down the machine.
4. Bin Control Troubleshooting
a) Machine Will Not Start
1) Confirm that the bin is not full. On the control board, if the yellow LED, BC OPEN, is
on, the bin control is the likely problem. If the green LED, BC CLOSED, is on, the bin
control is properly calling for ice. In this case, refer to section "IV. Service Diagnosis" to
verify that non-bin control related issues are resolved.
2) Check to make sure shipping tape has been removed and the wires are connected
properly.
3) Check to make sure no obstruction prevents the lever from moving to the bin empty
position.
4) Check proximity switch continuity to make sure it is not stuck open.
b) Machine Will Not Shut Off
1) Confirm that the bin is full and the actuator is in the bin full position. On the control
board, if the green LED, BC CLOSED is on, the bin control is the likely problem. If the
yellow LED, BC OPEN, is on, the bin control is properly showing that the bin is full. In
this case, refer to section "IV. Service Diagnosis" to verify that non-bin control related
issues are resolved.
2) Check to make sure no obstruction prevents the lever from moving to the bin full
position.
5. Float Switch Troubleshooting
Depending on local water conditions, scale may build up on the float switch. Scale on the
switch can cause the floats to stick. In this case, the float switch should be cleaned and
checked.
First, remove the switch from the water tank. Soak the switch assembly in ice machine
cleaner. While not necessary, the floats can be removed from the shaft during cleaning. If
you remove them, note that the blue float is on top. The floats must be installed with the
magnets inside them towards the top of the switch. Installing the floats upside down will
affect the timing of the float switch operation. Once clean, rinse and wipe the cleaner off.
Next, check the switch with an ohm meter. This float switch has three wires (the black
18
wire is common) and two separate switches. Check the upper switch by ohming out the
black and red wires. When the float is up, the switch should be closed. Check the lower
switch by ohming out the black and blue wires in the same manner. If either switch fails,
the assembly should be replaced.
Red (upper)
Black (common)
Blue (lower)
Magnet (towards top)
Upper Float (blue)
Spring Retainer Clip
Magnet (towards top)
Lower Float (white)
Plastic Retainer Clip
6. Control Board Check Procedure
Before replacing a control board 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.
1) Check the S4 dip switch settings to assure that they are in the factory default positions.
2) Turn the control switch to ICE and check for proper control voltage. If the red LED is on,
the control voltage is good. If the red LED is off, check the control transformer circuit.
3)Check the 115 volt input at the 10-pin connector. Check the brown and white wire at
pin #10 to a white neutral wire for 115 volts. (Always choose a white neutral wire to
establish a good neutral connection when checking voltages.) A jumper also feeds 115
volts into pin #7. If no voltage is present, check the 115 volt supply circuit.
4) The output test switch provides a relay sequence test. Make sure the control switch is in
the ICE position, then press the output test switch. The correct lighting sequence should
be none, 2, 3, 4, 1, and 4, normal sequence every 5 seconds. Components (e.g., the
compressor) will cycle during the test. Note that the order of the relays from the outer
edge of the board is 1, 4, 3, 2.
Note: If the LEDs light in a different sequence or the 5–second interval does not occur,
the control board is bad and should be replaced.
5) After checking the sequence, the unit automatically resumes normal operation after the
test. The unit begins normal operation with the 1 minute fill cycle.
19
7. Control Board Replacement
1) Unplug the unit from the electrical outlet and disconnect the wiring to the board.
2) Install the new board and make the wiring connections.
3) Set the application switch located between relays X3 & X4 to the ALP position. If this
switch is placed in the wrong position, the unit will not start.
4) Adjust the dip switches to the factory default settings. See "II.C.3.a) Default Dip Switch
Settings." S4 dip switch #8 must remain in the OFF position.
5) Plug the unit back in, then place the control switch in the ICE position. The red LED
should come on.
20
III. Technical Information
A. Water Circuit and Refrigeration Circuit
1. KM-255BAH (air-cooled)
Water
Supply
Harvest
Water
Valve
Wash Valve
Spray Tube
Condenser
Access Valve
High Pressure
Switch
Fan
Evaporator
Drier
Freeze
Water
Valve
Thermistor
Insulation Tube
Strainer
Hot Gas
Valve
Pump
Motor
Float
Switch
Suction
Line
Water Tank
Discharge Line
Compressor
Drain
Access Valve
Refrigerant Circuit
Expansion Valve
Water Circuit
21
2. KM-255BWH (water-cooled)
Water
Supply
Harvest
Water
Valve
Wash Valve
Access Valve
Condenser
Water Regulating
Valve
Drain
Spray Tube
Water
Supply
Evaporator
Drier
Freeze
Water
Valve
High Pressure
Switch
Thermistor
Insulation Tube
Strainer
Hot Gas
Valve
Pump
Motor
Float
Switch
Suction
Line
Water Tank
Discharge Line
Drain
Compressor
Access Valve
Refrigerant Circuit
Expansion Valve
Water Circuit
22
Contactor appearance
changed during 2006.
Earlier style is shown
here, and new style
is shown above in the
wiring diagram.
(Water
Valve
Relay)
(10.5 V)
B. Wiring Diagram
1. KM-255BAH (air-cooled)
*
* Pressure Switch
Cut-out
412±210 PSIG
Cut-in
327±21 PSIG
23
2. KM-255BWH (water-cooled)
Intentionally Left Blank
* Pressure Switch
Cut-out
384±21
0 PSIG
Cut-in
284±21 PSIG
24
C. Performance Data
1. KM-255BAH (air-cooled)
APPROXIMATE ICE
PRODUCTION PER 24 HR.
lbs./day kg./day
APPROXIMATE ELECTRIC
CONSUMPTION
watts
APPROXIMATE WATER
CONSUMPTION PER 24 HR.
3
gal./day m /day
FREEZING CYCLE TIME
min.
HARVEST CYCLE TIME
min.
HEAD PRESSURE
PSIG kg/cm2G
SUCTION PRESSURE
PSIG
2
kg/cm G
WATER TEMP. (ºF/ºC)
AMBIENT TEMP.
(ºF/ºC)
50/10
70/21
90/32
70/21
235
107
227
103
207
94
80/27
229
104
216
98
191
87
90/32
227
103
207
94
184
83
100/38
211
96
202
91
163
74
70/21
744
769
790
80/27
763
801
816
90/32
769
828
846
100/38
801
832
863
70/21
82
0.31
73
0.28
65
0.25
80/27
75
0.29
61
0.23
56
0.21
90/32
73
0.28
51
0.19
45
0.17
100/38
61
0.23
50
0.19
39
0.15
70/21
20
22
24
80/27
21
24
25
90/32
22
25
27
100/38
24
26
29
70/21
4.3
4
4
80/27
4
3.5
3
90/32
4
3.1
3
100/38
3.5
3
2.7
70/21
220
15.5
243
17.1
267
18.7
80/27
238
16.7
274
19.3
293
20.6
90/32
243
17.1
300
21.1
321
22.6
100/38
245
17.2
305
21.4
340
23.9
70/21
35
2.5
38
2.7
40
2.8
80/27
37
2.6
42
2.9
43
3.0
90/32
38
2.7
45
3.2
47
3.3
100/38
38
2.7
45
3.2
48
3.4
TOTAL HEAT OF REJECTION
4100 BTU/h [AT 90ºF (32ºC) / WT 70ºF (21ºC)]
Note:
1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold
should be used for reference only.
2. We reserve the right to make changes in specifications and design without prior
notice.
25
2. KM-255BWH (water-cooled)
Intentionally Left Blank
Note:
1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold
should be used for reference only.
2. We reserve the right to make changes in specifications and design without prior
notice.
26
IV. Service Diagnosis
A. 10-Minute Diagnostic Procedure
The 10 minute check out procedure is basically a sequence check which can be used
at unit start-up or for system diagnosis. Using this check out procedure will allow you
to diagnose electrical system and component failures in approximately 10 minutes
under normal operating conditions of 70°F or warmer air and 50°F or warmer water
temperatures. Before conducting a 10 minute checkout, check for correct installation,
proper voltage per unit nameplate and adequate water supply. As you go through the
procedure, check to assure the components energize and de-energize correctly. If not,
those components and controls are suspect. Check for voltage at the 10-pin connector.
1) Unplug the unit from the electrical outlet and access the control box and the electrical
box.
2) Plug the unit back in and place the control switch in the ICE position. The red LED on
the control board comes on. A 5 second delay occurs.
3) One Minute Fill Cycle – LED 4 is on. The freeze water valve is energized. After
1 minute, the control board checks for a closed lower float switch. If the lower float
switch is closed, the harvest cycle begins. If closed, continue to step 4. If the lower float
switch is open, the freeze water valve will remain energized through additional 1 minute
fill cycles until water enters the sump and the lower float switch closes (low water safety
protection during initial start up and at the end of each harvest). Diagnosis: If the
freeze water valve does not open, check for no supply voltage at water valve terminals,
bad coil, or plugged screen or external filter (no water flow). If unit fails to start harvest,
check for open lower float switch or bad 1 minute timer in board.
4) Initial Harvest Cycle – LEDs 1, 4 and 2 are on. The freeze water valve de-energizes
and the hot gas valve energizes (also energizing the water valve relay), the harvest
water valve energizes, and the contactor coil energizes to start the compressor.
The evaporator warms and the thermistor senses 48°F (9°C). The control board then
receives the thermistor's 3.9 kΩ signal and turns operation of harvest over to the
harvest timer. The timer completes counting (1 to 3 minutes – S4 dip switch 1 & 2).
The unit then cycles to freeze. The harvest water valve is open during harvest for a
maximum of 6 minutes or the length of harvest minus 50 seconds, whichever is shorter.
The pump motor energizes and runs for the last 50 seconds of harvest. Diagnosis:
Check if compressor is running, hot gas valve is open, harvest water valve open. If
these are okay, next check for at least 48°F (9°C) on the suction line. If cooler, check
for inlet water too cold, expansion valve stuck open, or water regulating valve (watercooled model) stuck open. If the suction line is at least 48°F (9°C), disconnect the
thermistor at the board (K3) and check for resistance of 3.9 kΩ or less. If different,
check and replace if necessary. See "II.C.3.b) Harvest Control – Thermistor," for check
procedure. If resistance is 3.9 kΩ or less, reconnect the thermistor to the board. If
harvest does not terminate within 3 minutes, replace the board.
5) Freeze Cycle – LED 1 is on. The compressor and pump motor remain energized and
the fan motor energizes. The hot gas valve de-energizes (also de-energizing the water
valve relay) and the harvest water valve de-energizes. The unit is held in freeze by a
5 minute short cycle protection timer. After 5 minutes, the freeze cycle operation is
transferred to the lower float switch for freeze termination. During the first 5 minutes
27
of freeze, confirm that the evaporator temperature drops. After 7 minutes in freeze,
disconnect the float switch by unplugging the harness from the K5 connector. The unit
should switch out of the freeze cycle.
Note: At this point, after the initial freeze cycle and every 10th cycle thereafter, LEDs
1, 3, and 2 come on, the compressor continues to run, the hot gas valve opens
and the fan motor de-energizes. The pump motor stops for 2 seconds. The pump
motor restarts and runs for 10 seconds.
Diagnosis: If the evaporator is not cold, check to see if the hot gas valve is still open
or if the expansion valve is not opening properly, if the harvest water valve or harvest
valves relay is stuck open (the freeze water valve will cycle on and off during freeze), if
there are improper unit pressures, or an inoperative compressor. If the unit remains in
freeze with the float switch removed, replace the board.
Note: Normal freeze cycle will last 20 to 40 minutes depending on model and
conditions. Cycle times and pressures should follow performance data provided
in this manual.
6) Normal Harvest Cycle – same as the initial harvest cycle – Return to step 4.
Note: Unit continues to cycle until bin control is satisfied or power is switched OFF. The
unit always restarts at the 1 minute fill cycle.
B. Diagnostic Charts
1. No Ice Production
Problem
Possible Cause
[1] The icemaker will not a) Power Supply
start.
Remedy
1. Off (breaker tripped or 1. Reset breaker or replace
fuse blown).
fuse.
2. Loose connection.
2. Tighten.
3. Bad contacts.
3. Check for continuity and
replace.
4. Voltage too high or too 4. Check and get
low.
recommended voltage.
b) Control Switch
1. OFF position.
1. Move to ICE position.
2. Bad contacts.
2. Check for continuity and
replace.
c) Fuse (internal)
1. Blown.
1. Check for short circuit and
replace.
d) Bin Control
1. Tripped with bin filled
with ice.
1. Remove ice.
2. Improperly activated.
2. Check for proper position
and movement.
1. Bad contacts.
1. Check for continuity and
replace.
2. Dirty air filter or
condenser.
2. Clean.
e) High Pressure Control
3. Ambient or condenser 3. Reduce temperature.
water temperature too
warm.
4. Refrigerant
overcharged.
28
4. Recharge.
Problem
Possible Cause
[1] The icemaker will not
start. (continued)
Remedy
5. Fan not operating.
(except water-cooled
model)
5. See chart 1.[6]
6. Refrigerant line or
6. Clean and replace drier.
components plugged.
7. Condenser water
7. Check and get
pressure too low or off. recommended pressure.
(water-cooled model
only)
f) Transformer
1. Coil winding opened
or shorted.
1. Replace.
g) Wiring to Control Board 1. Loose connections or 1. Check for continuity and
open.
replace.
h) Thermistor
1. Leads shorted or
1. See "II.C.3. Controls and
opened and high
Adjustments, b) Harvest
temperature or harvest Control."
backup timer safety
operates. (1 beep or 2
beep alarm)
i) Hot Gas Valve
1. Continues to open
in freeze cycle and
freeze timer safety
operates. (3 beep
alarm)
1. Check for hot gas valve
stuck open and replace.
j) Water Supply Line
1. Water supply off and
water supply cycle
does not finish.
1. Check and get
recommended pressure.
2. Condenser water
pressure too low
or off and pressure
control opens and
closes frequently to
finally operate high
temperature safety.
(1 beep alarm)
2. Check and get
recommended pressure.
1. Mesh filter or orifice
gets clogged and
water supply cycle
does not finish.
1. Clean.
2. Coil winding opened.
2. Replace.
k) Water Valves
3. Wiring to water valve. 3. Check for loose
connection or open, and
replace.
l) Control Board
1. Defective or in alarm.
1. See "II.C.6. Control Board
Check Procedure."
m)Control Switch
1. WASH position.
1. Move to ICE position.
2. Bad contacts.
2. Check and replace.
29
Problem
Possible Cause
[2] Water continues to
be supplied, and the
icemaker will not
start.
a) Float Switch
[3] Compressor will
not start or stops
operating.
Remedy
1. Connector
disconnected.
1. Place in position.
2. Leads opened or
defective switch.
2. Check and replace.
3. Float does not move
freely.
3. Clean or replace.
b) Control Board
1. Defective.
1. Replace.
c) Low Water Safety
1. Loose hose.
1. Check and reattach.
a) Magnetic Contactor
1. Bad contacts.
1. Check for continuity and
replace.
2. Coil winding opened.
2. Replace.
1. Defective.
1. Replace.
b) Start Capacitor
c) Internal Overload
1. Loose terminal.
Protector Open (check
1 through 3 to the right 2. Voltage.
and d through f below)
3. Dirty condenser.
3. Clean.
d) Starter
1. Bad contacts.
1. Check and replace.
2. Coil winding opened.
2. Replace.
e) Compressor
f) Control Board
1. Tighten or replace.
2. Check and correct.
1. Wiring to compressor. 1. Check for loose
connection or open, and
replace.
2. Defective.
2. Replace.
3. Protector tripped.
3. Reduce temperature.
1. No power to contactor. 1. See "II.C.6. Control Board
Check Procedure."
[4] Water continues to be a) Harvest Water Valve
supplied by harvest
water valve in freeze b) Water Valve Relay
cycle.
c) Control Board
1. Diaphragm does not
close.
1. Check for water leaks with
icemaker off.
1. Contacts stuck.
1. Replace.
1. Defective.
1. See "II.C.6. Control Board
Check Procedure."
[5] No water comes from a) Water Supply Line
spray tubes. Water
pump will not start, or
freeze cycle time is
b) Water Valves
too short.
1. Water pressure too
1. Check and get
low and water level in
recommended pressure.
water tank too low.
c) Water System
d) Pump Motor
1. Dirty mesh filter or
1. Clean.
orifice and water level
in water tank too low.
1. Water leaks.
1. Check connections for
water leaks, and replace.
2. Clogged.
2. Clean.
1. Motor winding opened. 1. Replace.
2. Bearing worn out.
2. Replace.
3. Wiring to pump motor. 3. Check for loose
connection or open, and
replace.
30
Problem
Possible Cause
Remedy
[5] No water comes from
spray tubes. Water
pump will not start, or
freeze cycle time is
too short. (continued) e) Control Board
4. Defective capacitor.
4. Replace.
5. Defective or bound
impeller.
5. Replace and clean.
1. Defective.
1. See "II.C.6. Control Board
Check Procedure."
[6] Fan motor will
not start, or is not
operating.
1. Motor winding opened. 1. Replace.
[7] All components
run, but no ice is
produced.
a) Fan Motor
2. Bearing worn out.
2. Replace.
3. Wiring to fan motor.
3. Check for loose
connection or open, and
replace.
4. Defective capacitor.
4. Replace.
5. Fan blade bound.
5. Check and replace.
b) Control Board
1. Defective.
1. See "II.C.6. Control Board
Check Procedure."
a) Refrigerant
1. Undercharged.
1. Check for leaks and
recharge.
2. Air or moisture
trapped.
2. Replace drier and
recharge.
b) Compressor
1. Defective valve.
1. Replace.
c) Hot Gas Valve
1. Continues to open in
freeze cycle.
1. Check and replace.
d) Harvest Water Valve
1. Water valve is wide
open during freeze.
1. Check for water leaks with
icemaker off.
e) Water Valve Relay
1. Contacts stuck.
1. Replace.
f) Water Supply Line
(water-cooled model
only)
1. Condenser water
1. Check and get
pressure too low or off
recommended pressure.
and pressure control
opens and closes
frequently.
g) Water Regulator
(water-cooled model
only)
1. Set too high or faulty.
31
1. Adjust or replace. See
"V.K. Adjustment of Water
Regulating Valve."
2. Evaporator is Frozen Up
Problem
Possible Cause
[1]Freeze cycle time is
too long.
a) Float Switch
1. Leads shorted or
defective switch.
1. Check and replace.
2. Float does not move
freely.
2. Clean or replace.
b) Water Valves
1. Diaphragm does not
close.
1. Check for water leaks with
icemaker off.
c) Control Board
1. Defective.
1. See "II.C.6. Control Board
Check Procedure."
1. Scaled up.
1. Clean.
1. Water pressure too
low.
1. Check and get
recommended pressure.
1. Dirty/Restricted
1. Replace filter.
1. Dirty mesh filter or
orifice.
1. Clean.
2. Diaphragm does not
close.
2. Check for water leaks with
icemaker off.
e) Ambient and/or water
temperature.
1. Too cool.
1. Increase temperature.
f) Thermistor
1. Out of position or
loose attachment.
1. See "V.L. Removal
and Replacement of
Thermistor."
g) Control Board
1. Harvest timer is set
too short.
1. Adjust longer, referring
to "II.C.3. Controls and
Adjustments, c) Harvest
Timer.
2. Defective.
2. See "II.C.6. Control Board
Check Procedure."
1. Clogged.
1. Clean
2. Out of position.
2. Place in position.
b) Water System
1. Dirty.
1. Clean.
c) Refrigerant
1. Undercharged.
1. Check for leaks and
recharge.
d) Expansion Valve
1. Bulb out of position or 1. Place in position.
loose attachment.
[2]All ice formed on
a) Evaporator
evaporator does not b) Water Supply Line
fall into bin in harvest
cycle.
c) Water Filter System
d) Water Valves
[3]Other
Remedy
a) Spray Tubes
e) Hot Gas Valve
f) Ice Cube Guides
2. Defective.
2. Replace.
1. Coil winding opened.
1. Replace.
2. Plunger does not
move.
2. Replace.
3. Wiring to hot gas
valve.
3. Check for loose
connection or open, and
replace.
1. Out of position and ice 1. Place in position.
trapped.
32
Problem
Possible Cause
Remedy
[3]Other (continued)
g) Water Supply Line
1. Too small; requires
1. Increase water line size.
3/8" OD line dedicated
per machine.
h) Water Filter
1. Flow rate too small.
1. Replace with filter that has
larger flow rate.
3. Low Ice Production
Problem
Possible Cause
Remedy
[1] Freeze cycle time is
long.
a) See chart 1.[3] and check dirty air filter or condenser, ambient or water
temperature, water pressure, condenser water regulating valve (water-cooled
model), and refrigerant charge.
b) See chart 2.[1] and check float switch, water valves and control board.
c) Check pump, hot gas valve, expansion valve, refrigerant charge, and
compressor.
[2] Harvest cycle time is a) See chart 2.[2] and check control board, thermistor, evaporator, ambient and/or
long.
water temperature, water supply line, water valves, and hot gas valve.
4. Abnormal Ice
Problem
Possible Cause
[1] Small cubes.
a) Ice Cube Guides
Remedy
1. Out of position.
Circulated water falls
into bin.
1. Place in position.
b) See chart 1.[5] and check water supply line, water valves, water system, pump
motor, and control board.
[2] Cloudy or irregular
cubes.
a) See chart 2.[1] and 2.[3], and check float switch, water valves, control board,
spray tubes, water system, refrigerant charge, and expansion valve.
b) Spray Guide
1. Dirty.
1. Clean.
c) Water Quality
1. High hardness or
contains impurities.
1. Install a water softener or
filter.
5. Other
Problem
Possible Cause
Remedy
[1] Icemaker will not stop a) Bin Control
when bin is filled with
ice.
1. See "II.C.4. Bin Control Troubleshooting."
[2] Abnormal noise.
a) Pump Motor
1. Bearings worn out.
1. Replace
b) Fan Motor
1. Bearings worn out.
1. Replace
2. Fan blade deformed.
2. Replace fan blade.
3. Fan blade does not
move freely.
3. Replace.
c) Compressor
d) Refrigerant Lines
1. Bearings worn out or 1. Replace.
cylinder valve broken.
2. Mounting pad out of
position.
2. Reinstall.
1. Rub or touch other
lines or surfaces.
1. Replace.
33
Problem
Possible Cause
Remedy
[3] Ice in storage bin
often melts.
a) Drain Line
1. Plugged.
1. Clean.
b) Ice Cube Guides
1. Out of position.
Circulated water falls
into bin.
1. Place in position.
34
V. Removal and Replacement of Components
IMPORTANT
Ensure all components, fasteners and thumbscrews are securely in place after
the equipment is serviced.
IMPORTANT
1. The Polyol Ester (POE) oils used in R-404A units can absorb moisture
quickly. Therefore it is important to prevent moisture from entering the system
when replacing or servicing parts.
2. Always install a new drier every time the sealed refrigeration system is
opened.
3. Do not leave the system open for longer than 15 minutes when replacing or
servicing parts.
A. Servicing the Refrigeration Circuit
1. Refrigerant Recovery
The icemaker unit is provided with two refrigerant access valves–one on the low-side and
one on the high-side line. Using proper refrigerant practices recover the refrigerant from the
access valves and store it in an approved container. Do not discharge the refrigerant into
the atmosphere.
2. Evacuation and Recharge (R-404A)
1) Attach service manifold hoses and a vacuum pump to the system. Be sure to connect
charging hoses to both high and low-side 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. Never allow the oil in the vacuum pump to flow backward.
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 service manifold.
5) Disconnect the vacuum pump, and attach a refrigerant service cylinder to the highside line. Remember to loosen the connection, and purge the air from the hose. See
the nameplate for the required refrigerant charge. Hoshizaki recommends only virgin
refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used.
6) A liquid charge is recommended for charging an R-404A system. Invert the service
cylinder and place it on scales. Open the high-side, service manifold valve.
7) Allow the system to charge with liquid until the nameplate weight is met.
35
8) If necessary, add any remaining charge to the system through the low-side. Use a
throttling valve or liquid dispensing device to add the remaining liquid charge through
the low-side access port with the unit running.
9) Close the two refrigerant access valves, and disconnect the service manifold hoses.
10) Cap the access valves to prevent a possible leak.
B. Brazing
DANGER
1. Refrigerant R-404A itself is not flammable at atmospheric pressure and
temperatures up to 176°F (80°C).
2. Refrigerant 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.
3. Always recover the refrigerant and store it in an approved container. Do not
discharge the refrigerant into the atmosphere.
4. Do not use silver alloy or copper alloy containing arsenic.
5. Do not use R-404A as a mixture with pressurized air for leak testing.
Refrigerant leaks can be detected by charging the unit with a little refrigerant,
raising the pressure with nitrogen and using an electronic leak detector.
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.
C. Removal and Replacement of Compressor
IMPORTANT
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.
Note: When replacing a compressor with a defective winding, be sure to install the
new start capacitor and start relay supplied with the replacement compressor.
Due to the ability of the POE oil in the compressor to absorb moisture quickly,
the compressor must not be opened more than 15 minutes for replacement or
service. Do not mix lubricants of different compressors even if both are charged
with R-404A, except when they use the same lubricant.
1) Unplug the unit from the electrical outlet.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the screws securing the electrical box (located over the compressor), then
slide out the box.
36
5) Remove the screws securing the compressor base and the condenser. On watercooled models, close the water supply line shut-off valve, drain the condenser and then
disconnect the water inlet and outlet at the condenser. Carefully slide the refrigeration
assembly forward.
6) Remove the terminal cover on the compressor, and disconnect the compressor wiring.
7) Remove the discharge and suction pipes.
8) Remove the hold-down bolts, washers and rubber grommets.
9) Remove the compressor. Unpack the new compressor package.
10) Attach the rubber grommets of the prior compressor.
11) Place the compressor in position, and secure it using the bolts and washers.
12) Remove the drier (located behind the upper, rear panel), then place the new drier in
position.
13) Remove plugs from the suction, discharge and process pipes.
14) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
15) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
16) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
17) Connect the terminals, and replace the terminal cover in its correct position.
18) Replace the removed parts in the reverse order of which they were removed. On watercooled models, open the water-supply line shut-off valve and check for leaks. Replace
the panels in their correct positions.
19) Plug the unit back in.
D. Removal and Replacement of Drier
IMPORTANT
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.
1) Unplug the unit from the electrical outlet.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the drier (located behind the upper, rear panel).
5) Install the new drier with the arrow on the drier in the direction of the refrigerant flow.
Use nitrogen gas at a pressure of 3 to 4 PSIG when brazing the tubings.
6) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
7) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
8) Replace the panels in their correct positions.
9) Plug the unit back in.
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E. Removal and Replacement of Expansion Valve
IMPORTANT
Sometimes moisture in the refrigeration circuit exceeds the drier capacity and
freezes up at the expansion valve. 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.
1) Unplug the unit from the electrical outlet.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the insulation and the expansion valve bulb on the suction line.
5) Remove the expansion valve cover, and then remove the expansion valve. Place the
new expansion valve in position.
6) Remove the drier (located below the expansion valve), then place the new drier in
position.
7) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
WARNING
Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 250°F (121°C).
8) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
9) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
10) Attach the expansion valve bulb to the suction line in the same location as the previous
bulb. The bulb should be at the 12 o'clock position on the tube. Be sure to secure the
bulb with the clamp and holder and to insulate it.
11) Place the expansion valve cover in position.
12) Replace the panels in their correct positions.
13) Plug the unit back in.
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F. Removal and Replacement of Hot Gas Valve
IMPORTANT
1. Always use a copper tube of the same diameter and length when replacing
the hot gas lines; otherwise the performance may be reduced.
2. 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.
3. Always replace the strainer when replacing the hot gas valve.
1) Unplug the unit from the electrical outlet.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the screws securing the electrical box (located over the compressor), then
slide out the box.
5) Remove the screws securing the compressor base and the condenser. On watercooled models, close the water supply line shut-off valve, drain the condenser and then
disconnect the water inlet and outlet at the condenser. Carefully slide the refrigeration
assembly forward.
6) Remove the screw and the solenoid.
7) Disconnect the hot gas valve and the strainer.
8) Place the new valve and new strainer in position.
9) Remove the drier (located behind the upper, rear panel), then place the new drier in
position.
10) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
CAUTION
Always protect the valve body by using a damp cloth to prevent the valve from
overheating. Do not braze with the valve body exceeding 250°F (121°C).
11) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
12) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
13) Cut the leads of the solenoid allowing enough lead length to reconnect using closed
end connectors.
14) Connect the new solenoid leads.
15) Attach the solenoid to the valve body, and secure it with a screw.
16) Replace the removed parts in the reverse order of which they were removed. On watercooled models, open the water-supply line shut-off valve and check for leaks. Replace
the panels in their correct positions.
17) Plug the unit back in.
39
G. Removal and Replacement of Evaporator
IMPORTANT
Always install a new drier every time the sealed refrigeration system is opened.
Do not replace the drier until after all other repairs or replacement have been
made.
1) Unplug the unit from the electrical outlet.
2) Close the water supply line shut-off valve.
3) Remove the panels.
4) Recover the refrigerant and store it in an approved container.
5) Disconnect all affected water hoses and remove the spray tube.
6) Remove the screws securing the mounting brackets, lift the evaporator up slightly and
disconnect the evaporator inlet tubing.
7) Lift up the evaporator, and disconnect the evaporator outlet tubing. Remove the
evaporator.
8) Remove the drier (located behind the upper, rear panel), then place the new drier in
position.
9) Install the new evaporator. Braze all fittings, including drier, while purging with nitrogen
gas flowing at a pressure of 3 to 4 PSIG.
10) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
11) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
12) Replace the removed parts in the reverse order of which they were removed.
13) Open the water supply line shut-off valve.
14) Plug the unit back in.
15) Check for leaks.
16) Replace the panels in their correct positions.
H. Removal and Replacement of Air-Cooled Condenser
1) Unplug the unit from the electrical outlet.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the screws securing the electrical box (located over the compressor), then
slide out the box.
5) Remove the screws securing the compressor base and the condenser. Carefully slide
the refrigeration assembly forward.
6) Disconnect the condenser inlet and outlet piping.
7) Remove the fan motor and shroud assembly from the old condenser and attach it to the
new condenser.
40
8) Place the new condenser in position.
9) Remove the drier (located behind the upper, rear panel), then place the new drier in
position.
10) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
11) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
12) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
13) Replace the removed parts in the reverse order of which they were removed, then
replace the panels in their correct positions.
14) Plug the unit back in.
I. Removal and Replacement of Water-Cooled Condenser
1) Unplug the unit from the electrical outlet.
2) Remove the panels.
3) Recover the refrigerant and store it in an approved container.
4) Remove the screws securing the electrical box (located over the compressor), then
slide out the box.
5) Remove the screws securing the compressor base and the condenser. Close the water
supply line shut-off valve, drain the condenser and then disconnect the water inlet and
outlet at the condenser. Carefully slide the refrigeration assembly forward.
6) Disconnect the condenser inlet and outlet piping from the refrigeration circuit.
7) Remove the mounting bracket from the old condenser and attach it to the new
condenser
8) Place the new condenser in position.
9) Remove the drier (located behind the upper, rear panel), then place the new drier in
position.
10) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG.
11) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
12) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
13) Replace the removed parts in the reverse order of which they were removed. Open the
water-supply line shut-off valve and check for leaks. Replace the panels in their correct
positions.
14) Plug the unit back in.
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J. Removal and Replacement of Water Regulating Valve Water‑Cooled Model Only
IMPORTANT
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.
1) Unplug the unit from the electrical outlet.
2) Close the condenser water supply line shut-off valve, and then drain the condenser.
3) Remove the panels.
4) Recover the refrigerant and store it in an approved container.
5) Disconnect the capillary tube at the condenser outlet.
6) Disconnect the flare-connections of the valve.
7) Remove the screws and the valve from the bracket.
8) Install the new valve, and braze the capillary tube.
9) Install the new drier.
10) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles.
11) Evacuate the system, and charge it with refrigerant. See the nameplate for the required
refrigerant charge.
12) Connect the flare-connections.
13) Open the water supply line shut-off valve.
14) Check for water leaks.
15) Replace the panels in their correct positions.
16) Plug the unit back in.
K. Adjustment of Water Regulating Valve - Water-Cooled Model Only
The water regulating valve (also called "water regulator") is factory-adjusted. No
adjustment is required under normal use. Adjust the water regulator, if necessary, using
the following procedures.
1) Prepare a thermometer to check the condenser drain temperature. Attach a pressure
gauge to the high-side line of the system.
2) Five minutes after a freeze cycle starts, confirm that the thermometer reads 104°F to
115°F (40°C to 46°C). If it does not, rotate the adjustment screw by using a flat blade
screwdriver until the temperature is in the proper range. Next, check that the reference
pressure is in the range indicated in the Head Pressure table in the Performance Data
section. If it is not in the proper range, verify the refrigerant charge.
42
3) Check that the condenser drain temperature is stable.
Adjustment
Screw
CW – Higher
CCW – Lower
Top View
L. Removal and Replacement of Thermistor
IMPORTANT
1. Fragile, handle very carefully.
2. Always use a recommended sealant (High Thermal Conductive Type), Model
KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y000-11,
or Part Code 4A0683-01 equivalent.
3. Always use a recommended foam insulation (non-absorbent type) or
equivalent.
4. Do not shorten or cut the thermistor leads when installing it.
1) Unplug the unit from the electrical outlet.
2) Remove the panels.
3) Disconnect the thermistor leads from the K3 connector on the control board.
4) Remove the plastic cable ties, foam
insulation, thermistor holder and thermistor.
Thermistor Lead
Cable Tie
5) Scrape away the old sealant on the
thermistor holder and the suction pipe.
6) Wipe off moisture or condensation on the
suction pipe.
7) Smoothly apply recommended sealant
(KE4560RTV, Part Code 60Y000-11
or 4A0683‑01) to the thermistor holder
concave.
Foam Insulation
Thermistor Holder
8) Attach the new thermistor to the suction pipe very carefully to prevent damage to the
leads. Secure it using the thermistor holder and recommended foam insulation.
9) Secure the insulation using plastic cable ties.
43
10) Connect the thermistor leads to the K3 connector on the control board.
Note: Do not cut the leads of the thermistor while installing it.
11) Replace the panels in their correct positions.
12) Plug the unit back in.
M. Removal and Replacement of Fan Motor
Note: When replacing a fan motor with defective winding, it is recommended that a new
capacitor be installed.
1) Unplug the unit from the electrical outlet.
2) Remove the panels.
3) Remove the screws securing the electrical box (located over the compressor), then slide
out the box.
4) Remove the screws securing the compressor base and the condenser. Carefully slide
the refrigeration assembly forward.
5) Remove the closed end connectors from the fan motor leads.
6) Remove the fan motor bracket and fan motor.
7) Remove the fan blade from the old fan motor and attach it to the new fan motor.
8) Install the new fan motor, and replace the removed parts in the reverse order of which
they were removed.
9) Replace the panels in their correct positions.
10) Plug the unit back in.
N. Removal and Replacement of Freeze or Harvest Water Valve
1) Unplug the unit from the electrical outlet.
2) Close the water supply line shut-off valve.
3) Remove the top panel and the insulation
panel.
Harvest
Water
Valve
4) Remove the thumbscrews and bracket
securing the valve mounting bracket and
the plastic water pan.
5) Loosen the fitting nuts. Be careful not to
lose the washers.
6) Disconnect the hoses and the terminals,
then remove the valve mounting bracket
from the unit.
Freeze
Water
Valve
7) Install the new water valve, and replace the removed parts in the reverse order of which
they were removed. Make sure the washers are in place in the fitting nuts.
8) Open the water supply line shut-off valve.
9) Plug the unit back in.
10) Check for leaks.
11) Replace the panels in their correct positions.
44
O. Removal and Replacement of Wash Valve
1) Unplug the unit from the electrical outlet.
2) Close the water supply line shut-off valve.
3) Remove the top panel and the insulation panel.
4) Remove the screws securing the valve to the bracket.
5) Disconnect the hoses and the terminals.
6) Note the orientation of the rubber grommet, then remove the rubber grommet and the
valve.
7) Put the rubber grommet on the new valve and then install the valve.
8) Replace the removed parts in the reverse order of which they were removed.
9) Open the water supply line shut-off valve.
10) Plug the unit back in.
11) Check for leaks.
12) Replace the panels in their correct positions.
P. Removal and Replacement of Pump Motor
1) Unplug the unit from the electrical outlet.
2) Remove the top panel and the insulation panel.
3) Disconnect the pump suction and discharge hoses.
Bracket (L)
Bracket (R)
4) Remove the water tank by pressing
down on the snaps on Bracket (L) and
Bracket (R) and pulling the tank towards
you.
5) Remove the drain pan assembly from
Bracket (R) by pulling it towards you. It is
snapped in place.
6) Disconnect the ground wire from the frame
and disconnect the pump wiring at the
connector.
7) Push up on the plastic tab securing the
water pump and slide the pump forward to
remove it.
Water
Tank
Bracket (R)
Drain Pan
Drain Tube
Frame/Pipe
8) Install the new pump, then replace the
removed parts in the reverse order of
which they were removed.
9) Plug the unit back in and check for leaks.
10) Replace the panels in their correct positions.
45
Q. Removal and Replacement of Spray Tube
1) Unplug the unit from the electrical outlet.
2) Remove the top panel and the insulation panel.
3) Remove the rubber hoses from the spray tube (water supply pipe).
4) Release the clamps, and disconnect the rubber hoses.
5) Remove the spray tube.
6) Install the new spray tube, and replace the removed parts in the reverse order of which
they were removed.
7) Replace the panels in their correct positions.
8) Plug the unit back in.
46
VI. Cleaning and Maintenance Instructions
IMPORTANT
Ensure all components, fasteners and thumbscrews are securely in place after
any maintenance or cleaning is done to the equipment.
A. Cleaning
WARNING
1. Hoshizaki recommends cleaning this unit at least once a year. More frequent
cleaning, however, may be required in some existing water conditions.
2. To prevent injury to individuals and damage to the icemaker, do not use
ammonia type cleaners.
3. Always wear liquid-proof gloves to prevent the cleaning and sanitizing
solutions from coming into contact with skin.
4. For safety and maximum effectiveness, use cleaning and sanitizing solutions
immediately after dilution.
1. Cleaning Procedure
1) Dilute 5 fl. oz. (148 ml) of recommended cleaner Hoshizaki "Scale Away" or "LIME-AWAY," (Economics Laboratory, Inc.) with 1 gallon (3.8 l) of warm water.
2) Remove the top panel and the insulation panel.
3) Remove all ice from the evaporator and the storage bin.
Note: To remove cubes on the evaporator, move the control switch on the control box to
the OFF position and move it back to the ICE position after 3 minutes. The defrost
cycle starts and the cubes will be removed from the evaporator.
4) Move the control switch to the OFF position. Open the door.
5) Disconnect the suction hose to drain the water. See Fig. 1.
Suction Hose
6) Reconnect the suction hose back in its correct position
after all of the water has drained.
Water Tank
7) Pour the cleaning solution into the water tank.
Drain
Pan
8) Move the control switch to the WASH position.
9) Close the door.
Fig. 1
10) After 30 minutes, move the control switch to the OFF position.
11) Disconnect the suction hose to drain the water. Reconnect the suction hose back in its
correct position after all of the water has drained.
12) Move the control switch to the ICE position to fill the water tank with water.
13) After 3 minutes, move the control switch to the WASH position.
14) After 5 minutes, move the control switch to the OFF position.
15) Disconnect the suction hose to drain the water. Reconnect the suction hose back in its
correct position after all of the water has drained.
16) Repeat steps 12 through 15 three more times to rinse thoroughly.
47
17) Remove the bin control switch housing at the back of the
water tank. It is snapped in place. Pinch it and then pull
down. See Fig. 2.
Water
Tank
Bin Control
Switch Housing
Fig. 2
Bracket (L)
Bracket (R)
18) Disconnect the suction hose. Next, remove the water
tank by pressing down on the snaps on Bracket (L) and
Bracket (R) and pulling the tank towards you. See Fig. 3.
Water
Tank
Fig. 3
19) Remove the float switch from the water tank by pulling out
on the right-side wall of the water tank slightly and sliding
the float switch upward. Be careful to avoid breakage
when handling the parts. See Fig. 4.
Float Switch
Detector
20) Remove the detector from the water tank. It is snapped in
place. Slide it up and then out. See Fig. 4.
21) Pull Cube Guide (A) and Cube Guide (B) (qty. varies
depending on model) upward to remove them from the
water tank. They are snapped in place. See Fig. 4.
Cube
Guide (A)
22) Remove the suction hose from the water tank.
Cube
Cube
Guide (B) Guide (A)
Water Tank Fig. 4
23) Remove the drain pan from Bracket (R) by pulling it
towards you. It is snapped in place. Remove the drain
tube and the frame/pipe from the drain pan. See Fig. 5.
24) Dilute 5 fl. oz. (148 ml) of recommended cleaner Hoshizaki
"Scale Away" or "LIME-A-WAY," (Economics Laboratory,
Inc.) with 1 gallon (3.8 l) of warm water.
25) Wash the bin control switch housing, water tank, float
switch, detector, Cube Guide (A), Cube Guide (B), suction
hose, drain pan, drain tube, and frame/pipe by using a
nylon scouring pad, brushes and the cleaning solution.
In addition to the removed parts, also wash the bin liner,
Bracket (L) and Bracket (R) with the solution.
Bracket (R)
Drain Pan
Drain Tube
Frame/Pipe
26) Discard the cleaning solution and rinse the parts thoroughly with water.
48
Fig. 5
2. Sanitizing Procedure - Following Cleaning Procedure
1) Dilute approximately 0.5 fl. oz. (15 ml or 1 tbs) of a 5.25% sodium hypochlorite solution
(chlorine bleach) with 1 gallon (3.8 l) of warm water. Using a chlorine test strip or other
method, confirm that you have a concentration of about 200 ppm.
2) Soak the removed parts from step 25 above in a clean container containing the
sanitizing solution. After allowing the parts to soak for 10 minutes, wash them with the
solution. Also wash the bin liner, Bracket (L) and Bracket (R) with the solution.
3) Discard the sanitizing solution and rinse the parts thoroughly with water.
4) Replace the removed parts in their correct positions in the reverse order of which they
were removed. Put the float switch wiring tubing in the slot to the right of the water tank
latch before putting the water tank in place.
5) Dilute approximately 0.5 fl. oz. (15 ml or 1 tbs) of a 5.25% sodium hypochlorite solution
(chlorine bleach) with 1 gallon (3.8 l) of warm water. Using a chlorine test strip or other
method, confirm that you have a concentration of about 200 ppm.
6) Pour the sanitizing solution into the water tank, and allow the sanitizer to sit for
10 minutes.
7) Move the control switch to the WASH position.
8) Close the door.
9) After 15 minutes, move the control switch to the OFF position.
10) Open the door.
11) Disconnect the suction hose to drain the water. Reconnect the suction hose back in its
correct position after all of the water has drained.
12) Repeat steps 5 through 11 one time.
13) Repeat steps 12 through 15 in the Cleaning Procedure three times to rinse thoroughly.
14) Flush the storage bin with water.
15) Move the control switch to the ICE position, and start the automatic icemaking process.
16) Close the door.
17) Replace the front panel in its correct position.
B. Maintenance
1. Exterior Panels
To prevent corrosion, wipe the exterior occasionally with a clean and soft cloth. Use a
damp cloth containing a neutral cleaner to wipe off oil or dirt build up.
2. Storage Bin and Scoop
• Wash your hands before removing ice. Use the plastic scoop provided (Accessory).
• The storage bin is for ice use only. Do not store anything else in the bin.
• Keep the scoop clean. Clean it by using a neutral cleaner and rinse thoroughly.
• Clean the bin liner by using a neutral cleaner. Rinse thoroughly after cleaning.
49
3. Air Filter (air-cooled model only)
The plastic mesh air filter removes dirt and dust from the air, and keeps the condenser
from getting clogged. As the filter gets clogged, the icemaker’s performance will be
reduced. Check the filter at least twice a month. When it is clogged, use warm water
and a neutral cleaner to wash the filter.
4. Condenser (air-cooled model only)
Check the condenser once a year and clean if required by using a brush or vacuum
cleaner. More frequent cleaning may be required depending on the location of the
icemaker.
C. Preparing the Icemaker for Long Storage
IMPORTANT
When shutting off the icemaker for an extended time, drain out all water from
the water lines and remove the ice from the storage bin. The storage bin should
be cleaned and dried. Drain the icemaker and water-cooled condenser (if
applicable) using air or carbon dioxide to prevent damage to the water supply
lines at sub-freezing temperatures. Shut off the icemaker until the proper
ambient temperature is resumed.
When the icemaker is not used for two or three days, it is sufficient to only move the control
switch to the OFF position, unless the icemaker will be at sub-freezing temperatures.
To drain all water from the icemaker, follow the steps below.
1) Remove the front panel, top panel and insulation panel.
2) Move the control switch on the control box to the OFF position.
3) Wait 3 minutes, then move the control switch to the ICE position.
4) Allow the icemaker to complete the one minute fill cycle (LED 4 is on), then move the
switch back to the OFF position.
5) Close the potable water supply line shut-off valve and open the potable water supply
line drain valve.
6) Allow the line to drain by gravity.
7) Move the control switch to the ICE position.
8) Blow the potable water supply line out using compressed air or carbon dioxide. This will
clear water from the freeze water valve.
9) Allow the machine to cycle from the one minute fill cycle to the initial harvest cycle
(LEDs 1, 4 and 2 are on). Blow the potable water supply line out using compressed air
or carbon dioxide. This will clear water from the harvest water valve.
10) Move the control switch to the OFF position.
11) Disconnect the suction hose to drain the water. See Fig. 1.
12) Disconnect the upper hose from the harvest water valve. Move the control switch to
the WASH position and quickly blow out the hose line using compressed air or carbon
dioxide. This will clear water from the wash valve.
50
13) Move the control switch to the OFF position.
14) Reconnect the suction hose and harvest water valve hose.
15) Close the potable water supply line drain valve.
16) Remove all ice from the storage bin and clean the bin.
17) Unplug the unit from the electrical outlet.
18) If the icemaker is water cooled, proceed to the next section to drain the condenser.
If the icemaker is air cooled, place the panels back in their correct positions. The
procedure is complete.
To drain all water from the water-cooled condenser, follow the steps below.
1) Close the water-cooled condenser water supply line shut-off valve.
2) Open the drain valve for the water-cooled condenser water supply line.
3) Allow the line to drain by gravity.
4) Attach compressed air or carbon dioxide supply to the condenser water supply line
drain valve.
5) Blow the water supply line out using compressed air or carbon dioxide until water stops
coming out.
6) Disconnect the water inlet and outlet at the condenser.
7) Remove the screws securing the compressor base and the condenser. Carefully slide
the refrigeration assembly forward.
8) Attach compressed air or carbon dioxide supply to the condenser and blow out the
condenser.
9) Close the condenser water supply line drain valve.
10) Place all removed parts back in their correct positions, and then place the panels back
in their correct positions.
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