Hoshizaki KM-1300SAH Bedienungsanleitung

NO: 73119 KM-1300SAH KM-1300SWH KM-1300SRH KM-1300SAH3 KM-1300SWH3 KM-1300SRH3 MODELS SER VICE MANU AL HOSHIZAKI STACKABLE CRESCENT CUBER ISSUED: Sep. 20, 2004[...]

2 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: (770) 487-3360 NOTE: To expedite assistance, all correspondence/communication MUST include the following information: • Model Number • Serial Number • Complete and det[...]

3 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 ............................[...]

4 IV . Ser vice Diagnosis .......................................................................................................... 43 1. No Ice Production ....................................................................................................... 43 2. Evapor ator is F rozen Up .........................................................[...]

5 I. Specifications 1. Icemaker KM-1300SAH A C S UP P LY V OLT A GE 208-230/60/ 1 (3 wire wit h neut ral for 115V ) A M P E RA GE 12. 6 A ( 5 Mi n. F reez e A T 104°F / W T 80°F ) M INIM UM CIRCUIT A M P A CIT Y 20 A MAX I MU M FU S E S I Z E 2 0 A APPR O X I MAT E I C E PRO D U C T I O N Amb ie n t W AT ER T EMP. ( ° F ) P E R 24 HR. T em p. (?[...]

6 KM-1300SWH We reserve the right to make changes in specifications and design without prior notice. A C S UP P LY V OLT A GE 208-230/60/ 1 (3 wire wit h neut ral for 115V ) A M P E RA GE 9. 7 A ( 5 Mi n. F reez e A T 104°F / W T 80°F) M INIM UM CIRCUIT A M P A CIT Y 20 A MAX I MU M FU S E S I Z E 20 A APPR O X I MAT E I C E PRO D U C T I O N Amb[...]

7 KM-1300SRH We reserve the right to make changes in specifications and design without prior notice. A C S UP P LY V OLT A GE 208-230/60/ 1 (3 wire wit h neut ral for 115V ) A M P E RA GE 14. 5 A ( 5 Mi n. F reez e A T 104°F / W T 80°F ) M INIM UM CIRCUIT A M P A CIT Y 20 A MAX I MU M FU S E S I Z E 2 0 A APPR O X I MAT E I C E PRO D U C T I O N [...]

8 KM-1300SAH3 We reserve the right to make changes in specifications and design without prior notice. AC S U PPLY VO L T A G E 2 0 8 - 23 0 /60 / 3 A M P E RA GE 7. 8 A ( 5 M i n. Freez e A T 104°F / W T 80°F) M INIM UM CIRCUI T A M P A CIT Y 20 A MAX I MU M FU S E S I Z E 2 0 A APPR O X I MAT E I C E PR OD U C T I ON Ambi e n t W AT ER T EMP. ( [...]

9 KM-1300SWH3 We reserve the right to make changes in specifications and design without prior notice. AC S U PPLY VO L T A G E 2 0 8 - 23 0 /60 / 3 A M P E RA GE 6. 9 A ( 5 M i n. Freez e A T 104°F / W T 80°F ) M INIM UM CIRCUI T A M P A CIT Y 2 0 A MAX I MU M FU S E S I Z E 20 A APPR O X I MAT E I C E PR OD U C T I ON Ambi e n t W AT ER T EMP. ([...]

10 KM-1300SRH3 We reserve the right to make changes in specifications and design without prior notice. AC S U PPLY VO L T A G E 2 0 8 - 23 0 /60 / 3 A M P E RA GE 10. 8 A ( 5 M i n. F reez e A T 104°F / W T 80°F ) M INIM UM CIRCUI T A M P A CIT Y 20 A MAX I MU M FU S E S I Z E 2 0 A APPR O X I MAT E I C E PR OD U C T I ON Ambi e n t W AT ER T EMP[...]

11 2. Condensing Unit URC-12F[...]

12 SPECIFICATIONS MODEL: URC-12F EXTERIOR DIMENSIONS (W x D x H) REFRIGERANT CHARGE URC-12F WEIGHT CONNECTIONS REFRIGERANT ELECTRICAL CONDENSER HEAD PRESSURE CONTROL AMBIENT CONDITION Galvanized Steel 35 - 11/16” x 15-11/16” x 21-15/16” (907.2 x 398 x 557.8 mm) R404A 4 lbs. 7 oz. (2000 g) Net 80 lbs. (36 kg) Shipping 87 lbs. (39 kg) One Shot [...]

13 II. General Information 1. Construction [a] KM-1300SAH, KM-1300SAH3[...]

14 [b] KM-1300SWH, KM-1300SWH3[...]

15 [c] KM-1300SRH, KM-1300SRH3[...]

16 2. Controller Board [a] Solid-State Control 1) A HOSHIZAKI exclusive solid-state control is employed in KM-1300SAH, KM-1300SWH, KM-1300SRH, KM-1300SAH3, KM-1300SWH3, and KM-1300SRH3 Stackable Crescent Cubers. 2) A printed circuit board (hereafter called “controller board”) includes a stable and high quality control system. 3) All models are [...]

17 (3) High Temperature Safety - 127 ± 7°F The temperature of the suction line in the refrigerant circuit is limited by the high temperature safety. During the defrost cycle the evaporator temperature rises. The thermistor senses 48°F and starts the defrost timer. After the defrost timer counts down to zero, the normal freeze cycle begins. If th[...]

18 The green LED’s 1-4 represent the corresponding relays and energize and sequence 5 seconds from initial startup as follows: Sequence Step LED’s on Length: Min. Max. Avg. 1 Minute Fill Cycle LED4 60 sec. Harvest Cycle LED1, 4, & 2 2 min. 20 min. 3-5 min. Freeze Cycle LED1 5 min. 60 min. 30-35 min. Reverse Pump Out LED1, 3, & 2 10 sec.[...]

19 The dip switches should be adjusted per the adjustment chart published in the Tech Specs book. 7 & 8 must remain in the OFF position. (Control Products HOS-001A Board)[...]

20 4. Defrost Timer stops counting. Defrost cycle is completed and freeze cycle starts. [c] Sequence 1st Cycle 1. Unit energized and Control Switch to “ICE” position. Water supply cycle starts. 2. After 1 minute. Defrost cycle starts. IMPORTANT Water Valve opening is limited to 6 minutes. 5. After the first 5 minutes in freeze cycle. Ready to c[...]

21 2nd Cycle and after with pump drain IMPORTANT Freeze cycle time is limited by the freeze timer factory setting even if the Float Switch does not open. 1. Float Switch opens and signals to complete freeze cycle. Drain timer starts counting. 2. Drain timer stops counting. Pump drain is completed 3. Thermistor reads 48° F. Defrost Timer starts cou[...]

22 2nd Cycle and after with no pump drain IMPORTANT Freeze cycle time is limited by the freeze timer factory setting even if the Float Switch does not open. 1. Float Switch opens and signals to complete freeze cycle. 2. Thermistor reads 48° F. Defrost Timer starts counting. IMPORTANT Water Valve opening is limited to 6 minutes. 4. After the first [...]

23 [d] Controls and Adjustments The dip switch is factory-adjusted to the following positions: Switch Nos. 1 and 2: Used for adjustment of the defrost timer. The defrost timer starts counting when the thermistor reads a certain temperature at the evaporator outlet. Switch Nos. 3 and 4: Used for adjustment of the drain timer. When a freeze cycle is [...]

24 1) Defrost Control A thermistor (semiconductor) is used for a defrost control sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the defrost timer. No adjustment is required. If necessary, check for resistance between thermistor leads, and visually ch[...]

25 3) Drain Timer The drain timer is factory-adjusted and no adjustment is required. SETTING TIME Dip Switch Dip Switch No. 3 No. 4 T 1 T 2 OFF OFF 10 seconds 150 seconds ON OFF 10 seconds 180 seconds OFF ON 10 seconds 120 seconds ON ON 20 seconds 180 seconds T1: Time to drain the water tank T2: Time to restrain defrost completion 4) Drain Counter [...]

26 5) Freeze Timer CA UTION Adjust to proper specification, or the unit may not operate correctly. The freeze timer is factory adjusted and no adjustment is required. This setting determines the maximum allowed freeze time to prevent possible freeze-up issues. SETTING TIME Dip Switch Dip Switch No. 9 No. 10 OFF OFF 60 min. ON OFF 70 min. OFF ON 50 [...]

27 (ii) After the above step (i), disconnect the float switch leads from the controller board within the first 5 minutes of the freeze cycle. The unit should go into the defrost cycle after the first 5 minutes ± 20 seconds of the freeze cycle. (iii) Reconnect the float switch connector to the controller board. After the first 5 minutes of the free[...]

28 III. T echnical Information 1. W ater Circuit and Refrigerant Cir cuit [a] KM-1300SAH, KM-1300SAH3[...]

29 [b] KM-1300SWH, KM-1300SWH3[...]

30 [c] KM-1300SRH, KM-1300SRH3[...]

31 Note: Pressure Switch KM-1300SAH Cut-out 41 2 PSIG Cut-in 327 ± 21.3 PSIG +21.3 0 2. Wiring Diagrams [a] KM-1300SAH, KM-1300SWH KM-1300SWH Cut-out 3 84 PSIG Cut-in 285 ± 21.3 PSIG +21.3 0[...]

32 [b] KM-1300SRH Note: Pressure Switch Cut-out 41 2 PSIG Cut-in 327 ± 21.3 PSIG +21.3 0[...]

33 [c] KM-1300SAH3, KM-1300SWH3 Note: Pressure Switch KM-1300SAH3 Cut-out 4 12 PSIG Cut-in 327 ± 21.3 PSIG +21.3 0 KM-1300SWH3 Cut-out 38 4 PSIG Cut-in 285 ± 21.3 PSIG +21.3 0[...]

34 [d] KM-1300SRH3 Note: Pressure Switch Cut-out 41 2 PSIG Cut-in 327 ± 21.3 PSIG +21.3 0[...]

35 3. Timing Char t[...]

36[...]

37 4. Perf ormance Data [a] KM-1300SAH Note: Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. 70/ 21 1283 582 1242 563 1135 51 5 80/ 27 1252 568 1188 539 1053 47 8 90/ 32 1242 563 1143 518 1017 4[...]

38 [b] KM-1300SWH Note: Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. 70/ 21 1284 582 1282 582 1208 54 8 80/ 27 1283 582 1280 581 1166 52 9 90/ 32 1282 582 1278 580 1 180 535 lb s./d a y kg ./[...]

39 [c] KM-1300SRH Note: Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. 70/ 21 1296 588 1257 570 1173 53 2 80/ 27 1266 574 1206 547 1105 50 1 90/ 32 1257 570 1163 528 1068 484 lb s./d a y kg ./d[...]

40 [d] KM-1300SAH3 Note: Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. 70/ 21 1320 599 1265 574 1153 52 3 80/ 27 1278 580 1192 541 1060 48 1 90/ 32 1265 574 1132 513 1006 456 lb s./d a y kg ./[...]

41 [e] KM-1300SWH3 Note: Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. 70/ 21 1254 569 1264 573 1191 54 0 80/ 27 1261 572 1276 579 1157 52 5 90/ 32 1264 573 1287 584 1 186 538 lb s./d a y kg .[...]

42 [f] KM-1300SRH3 Note: Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. 70/ 21 1308 593 1296 588 1203 54 6 80/ 27 1299 589 1279 580 1145 52 0 90/ 32 1296 588 1266 574 1148 521 lb s./d a y kg ./[...]

43 IV . Service Diagnosis 1. No Ice Production P ro bl em P o ssi b l e Cause Rem edy [ 1] a) P ower S upply 1. O FF pos it ion. 1. Mov e t o ON pos it ion. 2. Loos e c onnec t i on. 2. T ight en. 3. B ad c ont ac t s . 3. Che c k f or c ont i nui t y and replac e. 4. V olt age too hi gh. 4. Chec k and get rec om m ended v ol t age. b) F us e (I ns[...]

44 Pr o ble m Po s s ible C au s e R e med y [1 ] C o nti n u e d fr om prev i ous page. j) W a te r Su p p ly L in e 1 . W a te r sup p ly o ff a n d w a te r s upply c y c le does not fin ish . 1. Chec k and get rec om m ended pres s ure. 2. Cond ens er w at er pres s ure to o lo w o r off a n d p r e ssu r e c ontrol opens and c los es fr eq u e[...]

45 P ro bl em P o ssi b l e Cause Rem edy [ 3] c ) Ov erload P rot ec t or 1. B ad c ont ac t s . 1. Chec k f or c ont i nuit y and replac e. 2. V olt age t oo low. 2. I nc reas e v olt age. 3. Ref ri gerant ov erc harged or underc harged. 3. Recharge. 4. Li ne v alv e c ont inues t o cl o se i n fr e e ze cycle a n d ov er l oad prot ec t or opera[...]

46 P ro bl em P o ssi b l e Cause Rem edy [ 5] d) P ump M ot or 1. M ot or w indi ng opened. 1. Rep l ac e. 2. B earing wor n out . 2. Rep l ac e. 3 . W ir in g to pu mp mo to r . 3 . C he ck for l o o se c onnec t i on or ope n, and replac e. 4. Def ec t i v e c apac it or. 4. Rep l ac e. 5. Def ec t i v e or bound imp e lle r . 5. Rep l ac e and [...]

47 2. Evaporator is Frozen Up P ro bl em P o ssi b l e Cause Rem edy [ 1] a) Fl oat S wit c h 1 . Leads s hort -c irc ui t or d e fe cti ve sw i tch . 1. Che c k and r eplac e. 2. F l oat does not m ov e f reely . 2. Clean or re pl ac e. b) Wat er S ol enoid V alv e 1. Diaphragm does not c l os e. 1. Chec k f or w at er leak s wit h ic em ak er of [...]

48 3. Low Ice Production 4. Abnormal Ice 5. Other P ro bl em P o ssi b l e Cause Rem edy [ 1] a) B i n Cont rol T hermos t at 1. S et t oo c old. 1. A dj us t warmer. 2. D ef ec t iv e. 2. Replac e. [2 ] A bnormal nois e. a) P ump M ot or 1 . B eari ngs worn out. 1. Replac e. b) Fan M ot or 1. B eari ngs worn out. 1. Replac e. 2. F an blade def orm[...]

49 V . Remov al and Replacement of Components IMPORT ANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORT ANT 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 servicin[...]

50 5) Disconnect the vacuum pump, and attach a refrigerant service cylinder to the high-side line. Remember to loosen the connection, and purge the air from the hose. For air-cooled and water- cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled models, see the charge label in the machine compartment. Hoshizak[...]

51 3. Removal and Replacement of Compressor IMPORT ANT 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 wi[...]

52 16) Connect the terminals, and replace the terminal cover in its correct position. 17) Replace the panels in their correct positions. 18) Turn on the power supply. 4. Removal and Replacement of Drier IMPORT ANT Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repair o[...]

53 5. Remov al and Replacement of Expansion V alve IMPORT ANT Sometimes moisture in the refrigerant 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) Turn off[...]

54 6. Remo val and Replacement of Hot Gas V alve and Line V alve CA UTION Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced. IMPORT ANT Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repa[...]

55 7. Removal and Replacement of Evaporator IMPORT ANT 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) Turn off the power supply. 2) Remove the panels and the top insulation over the evaporator. 3) Recover the refrigerant and stor[...]

56 8. Remov al and Replacement of W ater Regulating V alve - W ater-Cooled Model Only IMPOR T ANT 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) Turn off the power supply. 2) Close the water supply line shut-off valve. 3) Remove [...]

57 9. Adjustment of W ater Regulating V alve - W ater-Cooled Model Onl y 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) Attach a pressure gauge to the high-side line of the system. Or prepa[...]

58 10. Remov al and Replacement of Condensing Pressure Regulator (C.P .R.) - Remote Air-Cooled Model Only IMPORT ANT 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) Turn off the power supply. 2) Remove the panels from the remote c[...]

59 11. Remo v al and Replacement of Thermistor CA UTION 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. 1) T[...]

60 12. 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) Turn off the power supply. 2) Remove the panels. 3) Remove the junction box cover from the remote condenser unit (remote air-cooled model). 4) Remove the closed end connectors from the fan moto[...]

61 13. Remov al and Replacement of W ater V alve 1) Turn off the power supply. 2) Close the water supply line shut-off valve. 3) Remove the front panel. 4) Remove the valve outlet tubing by releasing the clamp. 5) Remove the bracket from the unit. 6) Remove the fitting nut and water valve. 7) Disconnect the terminals from the water valve. 8) Instal[...]

62 7) Remove the closed end connectors from the pump motor leads. 8) Remove the two screws and the pump motor bracket. 9) Remove the pump housing and check the impeller. 10) If the impeller is defective, install a new impeller. 11) Install the new motor or new parts, and replace the removed parts in the reverse order of which they were removed. 12)[...]

63 1. Preparing the Icemaker for Long Storage W ARNING When shutting off the icemaker for an extended time, drain out all water from the water tank and remove the ice from the storage bin. The storage bin should be cleaned and dried. Drain the icemaker to prevent damage to the water supply line at sub-freezing temperatures, using air or carbon diox[...]

64 [2] Remove the water from the potable water supply line: 1) Remove the front panel. (Except water-cooled model) 2) Move the control switch on the control box to the “ OFF ” position. 3) Wait 3 minutes. 4) Close the potable water supply line shut-off valve and open the potable water supply line drain valve. 5) Allow the line to drain by gravi[...]

65 2. Cleaning and Sanitizing Procedures IMPOR T ANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. W ARNING 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 pr[...]

66 [a] Cleaning Procedure 1) Dilute 27 fl. oz. of the recommended cleaner Hoshizaki “ Scale Away ” or “ LIME-A-WAY ” (Economics Laboratory, Inc.) with 5 gal. of water. 2) Remove all ice from the evaporator and the storage bin. Note: To remove cubes on the evaporator, turn off the power supply and turn it on after 3 minutes. The defrost cycl[...]

67 19) Turn on the power supply to fill the water tank with water. 20) Turn off the power supply after 3 minutes. 21) Remove the front panel, and fully open the cleaning valve. 22) Move the control switch to the “ WASH ” position. 23) Replace the front panel in its correct position. 24) Turn on the power supply to rinse off the cleaning solutio[...]

68 [b] Sanitizing Procedure - Following Cleaning Procedure 1) Dilute a 5.25% sodium hypochlorite solution (chlorine bleach) with water (Add 2.5 fl. oz. of sanitizer to 5 gal. of water). 2) Remove the insulation panel, if it is in its normal position. 3) Pour the sanitizing solution into the water tank. 4) Replace the insulation panel and the front [...]

69 3. Maintenance IMPOR T ANT This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. 1) Stainless Steel Exterior 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) Stora[...]