Hoshizaki KM2000SWF3 manual

ISSUED: OCT . 9, 1998 KM-2000SWF3 KM-2000SRF3 KM-2000SWH3 KM-2000SRH3 MODEL SER VICE MANUAL HOSHIZAKI STACKABLE CRESCENT CUBER NO: 73081 DEC. 16, 2003 REVISED:[...]

2 HOSHIZAKI AMERICA, INC. 618 Highway 74 South Peachtree City , GA 30269 Attn: HOSHIZAKI T echnical Support Department Phone: 1-800-233-1940 T echnical Service (770) 487-2331 Fax: (770) 487-3360 NOTE: T o expedite assistance, all correspondence/communication MUST include the following information: • Model Number • Serial Number • Complete and[...]

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 PAGE I. SPECIFICATIONS .......................[...]

4 2. BRAZING ............................................................................................................. 37 3. REMOVAL AND REPLACEMENT OF COMPRESSOR ...................................... 38 4. REMOVAL AND REPLACEMENT OF DRIER .................................................... 39 5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE ...[...]

5 I. SPECIFICATIONS 1. KM-2000SWF3, KM-2000SWH3 (Water-cooled) We reserve the right to make changes in specifications and design without prior notice.[...]

6 2. KM-2000SRF3, KM-2000SRH3 (Remote air-cooled) We reserve the right to make changes in specifications and design without prior notice.[...]

7 3. CONDENSING UNIT URC-20F[...]

8 SPECIFICATIONS MODEL: URC-20F EXTERIOR DIMENSIONS (W x D x H) REFRIGERANT CHARGE URC-20F WEIGHT CONNECTIONS REFRIGERANT ELECTRICAL CONDENSER HEAD PRESSURE CONTROL AMBIENT CONDITION Galvanized Steel 46 - 3/8" x 15 - 11/16" x 25 - 15/16" (1178 x 398 x 659 mm) R404A 7 lbs.11 oz. (3500 g) Net 104 lbs. (47 kg) Shipping 150 lbs. (52 kg) [...]

9 Evaporator Spray Tube Water Valve Expansion Valve Water Supply Inlet Check Valve Hot Gas Valve Junction Box Control Box Water-cooled Condenser Line Valve Water Regulator Water Pump Float Switch Transformer Box Cleaning Valve Drier Compressor Control Switch Bin Control Thermostat II. GENERAL INFORMA TION 1. CONSTRUCTION [a] KM-2000SWF3, KM-2000SWH[...]

10 [b] KM-2000SRF3, KM-2000SRH3 Evaporator Spray Tube Water Valve Expansion Valve Water Supply Inlet Check Valve Hot Gas Valve Junction Box Control Box Receiver Tank Water Pump Line Valve Float Switch Transformer Box Cleaning Valve Drier Compressor Control Switch Bin Control Thermostat[...]

11 2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KM-2000SWF3, KM-2000SRF3, KM-2000SWH3, and KM-2000SRH3 Stackable Crescent Cubers. 2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and high quality control system. 3) All models are pretested and factory-a[...]

12 2) Defrost Timer The defrost cycle starts when the Float Switch opens and completes the freeze cycle. But the Defrost Timer does not start counting until the Thermistor senses 48°F at the Evapora- tor outlet. The period from the end of the freeze cycle up to the point of the Thermistor's sensing varies depending on the ambient and water te[...]

13 problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A short beep occurs when the power switch is turned ON or OFF. 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 [...]

14 (Control Products HOSHIZAKI001 Board) to the K1 connector. If there is a white wire, place the switch in the C position. If this switch is placed in the wrong position either the compressor contactor will remain ener- gized with the control switch OFF or the unit will not start. The dip switches should be adjusted per the adjustment chart publis[...]

15 (Control Products HOS-001A Board)[...]

16 4. Defrost Timer stops counting. Defrost cycle is completed and freeze cycle starts. [c] SEQUENCE 1st Cycle [KM-2000SWF3, KM-2000SRF3, KM-2000SWH3 and KM-2000SRH3] 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. [...]

17 2nd Cycle and after with pump drain [KM-2000SWF3, KM-2000SRF3, KM-2000SWH3 and KM-2000SRH3] IMPORTANT Freeze cycle time is limited to 60 minutes even if 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[...]

18 2nd Cycle and after with no pump drain [KM-2000SWF3, KM-2000SRF3, KM-2000SWH3 and KM-2000SRH3] IMPORTANT Freeze cycle time is limited to 60 minutes even if 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 [...]

19 DIP SWITCH NO. 1 2 3 4 5 6 7 8 9 10 OFF OFF ON ON ON ON OFF OFF OFF OFF [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. [...]

20 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[...]

21 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[...]

22 6) Bin Control CAUTION When the ambient temperature is below 45°F, the Bin Control Thermostat operates to stop the icemaker even if the Ice Storage Bin is empty. When the Thermostat is set in the prohibited range, the icemaker operates con- tinuously even if the Ice Storage Bin is filled with ice. Setting in the prohib- ited range might cause s[...]

23 (iv) After Step (iii), de-energize the unit and confirm that the Defrost Timer is in the minimum position. Disconnect the resistor from the Controller Board, and energize the unit. After the 1 minute water supply cycle, the defrost cycle starts. Re-connect a 1.5 k Ω - 3.5 k Ω resistor to the Connector K3 (pins #1 and #2) after the first 2 mi[...]

24 III. TECHNICAL INFORMA TION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] KM-2000SWF3, KM-2000SWH3[...]

25 [b] KM-2000SRF3, KM-2000SRH3[...]

26 2. WIRING DIAGRAMS [a] KM-2000SWF3 KM-2000SWH3 [b] KM-2000SRF3 KM-2000SRH3 Pressure Switch Cut-out 384 PSIG Cut-in 284 ± 21.3 PSIG +21.3 0 Pressure Switch Cut-out 41 2 PSIG Cut-in 327 ± 21.3 PSIG +21.3 0 KM-2000SWF3, KM-2000SWH3 KM-2000SRF3, KM-2000SRH3[...]

27 3. TIMING CHART *1 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”[...]

28 *1 The Pump Motor waits for 2 seconds before starting a drain cycle. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.” *2 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”[...]

29 4. PERFORMANCE DATA [a] KM-2000SWF3, KM-2000SWH3 Note: Pressure data is recorded first 5 minutes in freezing cycle. The data not in bold should be used for reference. We reserve the right to make changes in specifications and design without prior notice.[...]

30 [b] KM-2000SRF3, KM-2000SRH3 Note: Pressure data is recorded first 5 minutes in freezing cycle. The data not in bold should be used for reference. We reserve the right to make changes in specifications and design without prior notice.[...]

31 PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker a) Power Supply 1. “OFF” position. 1. Move to “ON” position. will not start 2. Loose connections. 2. Tighten. 3. Bad contacts. 3. Check for continuity and replace. 4. Voltage too high. 4. Check and get recommended voltage. b) Fuse (Inside Fused 1. Blown out. 1. Check for short circuit Discon[...]

32 PROBLEM POSSIBLE CAUSE REMEDY l) Controller Board 1. Defective. 1. See “II.2[e] CHECKING CONTROLLER BOARD.” m) Interlock Switch 1. “OFF” position. 1. Move to “ON” position. (Cleaning Valve) 2. Bad contacts. 2. Check for continuity and replace. [2] Water a) Float switch 1. Connector disconnected. 1. Place in position. continues to 2. [...]

33 PROBLEM POSSIBLE CAUSE REMEDY [5] No water a) Water Supply Line 1. Water pressure too low and 1. Check and get comes from water level in Water Tank recommended pressure. Spray Tubes. too low. Water Pump b) Water Solenoid 1. Dirty mesh filter or orifice 1. Clean. will not start, or Valve and water level in Water freeze cycle Tank too low. time is[...]

34 2. EV APORA TOR IS FROZEN UP PROBLEM POSSIBLE CAUSE REMEDY [1] Freeze cycle a) Float Switch 1. Leads short-circuit or 1. Check and replace. time is too defective switch. long. 2. Float does not move freely. 2. Clean or replace. b) Water Solenoid 1. Diaphragm does not close. 1. Check for water leaks Valve with icemaker off. c) Controller Board 1.[...]

35 PROBLEM POSSIBLE CAUSE REMEDY [1] Icemaker will a) Bin Control 1. Set too cold. 1. Adjust warmer. not stop when Thermostat 2. Defective. 2. Replace. bin is filled with ice. [2] Abnormal a) Pump Motor 1. Bearings worn out. 1. Replace. noise b) Fan Motor 1. Bearings worn out. 1. Replace. 2. Fan blade deformed. 2. Replace fan blade. 3. Fan blade do[...]

36 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[...]

37 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 water-cooled models, see the Nameplate for the required refrigerant charge. For remote air-cooled models, see the Charge Label in the machine compartment. Hoshizaki recommends on[...]

38 3. REMOV AL 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 w[...]

39 15) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required refrigerant charge. 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. REMOV AL AND REPLACEMENT OF DRIER IMPORT ANT Always install a new Dr[...]

40 5. REMOV AL AND REPLACEMENT OF EXP ANSION V AL VE 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 o[...]

41 6. REMOV AL AND REPLACEMENT OF HOT GAS V AL VE AND LINE V AL VE CAUTION 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 rep[...]

42 11) Connect the new Solenoid leads. 12) Attach the Solenoid to the valve body, and secure it with a screw. 13) Replace the panels in their correct positions. 14) Turn on the power supply. 7. REMOV AL AND REPLACEMENT OF EV APORA T OR IMPORT ANT Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Dri[...]

43 8. REMOV AL AND REPLACEMENT OF W A TER REGULA TING V AL VE - W A TER-COOLED MODEL ONL Y 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) Close the Water Supply Line Shut-off Valve. 3) Rem[...]

44 9. ADJUSTMENT OF W A TER REGULA TING V AL VE - W A TER-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 prep[...]

45 10. REMOV AL AND REPLACEMENT OF CONDENSING PRESSURE REGULA TOR (C.P .R.) - REMOTE AIR-COOLED MODEL ONL Y 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[...]

46 Foam Insulation Thermistor Holder Thermistor Lead Cable Tie Fig. 2 1 1. REMOV AL AND REPLACEMENT OF THERMISTOR CAUTION 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 re[...]

47 12. REMOV AL AND REPLACEMENT OF F AN MOTO R 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 M[...]

48 13. REMOV AL AND REPLACEMENT OF W A TER V AL VE 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) Inst[...]

49 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[...]

50 VI. CLEANING AND MAINTENANCE INSTRUCTIONS 1. PREP ARING THE ICEMAKER FOR LONG STORAGE IMPORT ANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. W ARNING When shutting off the icemaker for an extended time, drain out all water from the water tank and remove the ic[...]

51 [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[...]

52 2. CLEANING PROCEDURE IMPORT 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 prevent injury to i[...]

53 [a] CLEANING PROCEDURE 1) Dilute 38 fl. oz. of the recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 7 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 cycle st[...]

54 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 solution.[...]

55 [b] SANITIZING PROCEDURE - Following Cleaning Procedure 1) Dilute a 5.25% Sodium Hypochlorite solution (chlorine bleach) with water (Add 3.5 fl. oz. of sanitizer to 7 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 [...]

56 3. MAINTENANCE IMPORT 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) Storag[...]