Hoshizaki KMD-410MWH manual

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ii C O N T E N T S PAGE I. SPECIFICATIONS --------------------------------------------------------------------------------------- 1 1. SPECIFICATIONS----------------------------------------------------------------------------------- 1 [a] KMD-410MAH (air-cool ed) --------------------------------------------------------------------- 1 [b] KMD-410MWH[...]

iii 1. 10-MINUTE DIAGNOSTIC PROCEDURE ----------------------------------------------------- 27 2. DIAGNOSTIC CHARTS----------------------------------------------------------------------------- 29 [a] NO ICE PR ODUCTION ------------------------------------------------------------------------ 29 [b] EVAPORATOR IS FROZEN UP ---------------------------[...]

1 AC SUPPLY VOLTAGE 115/60/1 㩷 AMPERAGE 8.0 A (5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day (kg/day) 70 *415 (188) 388 (176) 354 (160) Reference without *marks 80 395 (179) 353 (160) 320 (145) 90 388 (176) *324 [...]

2 [b] KMD-410MWH (water-cooled) AC SUPPLY VOLTAGE 115/60/1 㩷 AMPERAGE 6.5 A (5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day (kg/day) 70 *440 (200) 423 (192) 392 (178) Reference without *marks 80 427 (194) 401 (182[...]

3 II. GENERAL INFORMATION 1. CONSTRUCTION [a] KMD-410MAH Spray Guide Spray Tube Drain Valve Water Supply Inlet Water Tank Cube Guide Pump Motor Float Switch Condenser Fan Motor Hot Gas Valve Compressor Control Box Expansion Valve Harvest Water Valve Fill Water Valve Control Switch Service Switch Fuse Holder (Fuse) Bin Control Switch Drier Thermisto[...]

4 [b] KMD-410MWH Spray Guide Spray Tube Drain Valve Water Supply Inlet Water Tank Cube Guide Pump Motor Float Switch Water Regulator Condenser Hot Gas Valve Compressor Control Box Expansion Valve Harvest Water Valve Fill Water Valve Control Switch Service Switch Fuse Holder (Fuse) Bin Control Switch Drier Thermistor Access Valve (Low Side) Access V[...]

5 2. SEQUENCE OF OPERATION The steps in the sequence are as outlined below. When power is supplied, a 5 second delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is 5, 6, 8, 9, 4, 7. [a] ONE MINUTE FILL CYCLE LED 8 is on. HWV opens and the fill period begins. After 1 minute, the board checks for a closed LF/S.[...]

6 [e] NORMAL HARVEST CYCLE LEDs 5, 6, and 8 are on. Comp continues to run, HGV remains open and HWV opens. As the evaporator warms, the thermistor reaches 9ºC. The control board then receives the thermistor’s 3.9k signal and starts the harvest timer. HWV is open during harvest for a maximum of 6 minutes or the length harvest minus 0, 10, 30, [...]

7 KMD-410MAH, 410MWH “H” board will have 5 second delay x Maximum harvest water valve time: 6 minutes (HWV time is 6 minutes of the length of harvest minus 0, 10, 30, or 50 sec. (S1 dip switch 7 & 8), whichever is shorter. PM energizes and runs for the last 0, 10, 30, or 50 sec. of harvest.) x Maximum harvest time: 20 minutes x Minimum free[...]

8 3. CONTROL BOARD * A HOSHIZAKI exclusive solid-state control is employed in KMD-410MAH and KMD-410MWH Crescent Cubers. * All models are pretested and factory-adjusted. 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 th[...]

9 [a] CONTROL BOARD LAYOUT #4 Harvest Water Valve #5 Freeze Water Valve #1, 2, 3 Float Switch Control Board Auxiliary Code V1 or Earlier V2 or Later Part Number P00013-02 P01771-02 T ype HKM2006V003[...]

10 [b] 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 0, 10, 30, or 50 seconds (adjustable by S dip switch 7 & 8), whichever is shorter. b) Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if, for two cycle[...]

11 f) LED Lights and Audible Alarm Safeties The control board includes LED indicator lights, audible alarm safeties, and an output test feature. The "POWER OK" LED indicates control voltage and will remain on unless a control voltage problem occurs. The “POWER OK” LED flashes continuously when the bin is full and DV energizes for a ma[...]

12 [c] CONTROLS AND ADJUSTMENTS a) Default Dip Switch Settings The dip switch is factory-adjusted to the following positions: S1 Dip Switch No. 1 2 3 4 5 6 7 8 9 10 KMD-410MAH OFF OFF OFF OFF ON ON ON ON OFF OFF KMD-410MWH OFF OFF OFF OFF ON ON ON ON ON OFF S2 Dip Switch * Functions of S2 dip switch nos. 2 through 6 depend on program ve rsion. Do n[...]

13 c) Drain Timer (S1 dip switch 3 & 4) Once every ten freeze cycles, the drain valve opens to drain the water tank for the time determined by the drain timer. These switches also determine the time to delay completion of a defrost cycle, i.e. the minimum defrost time. Do not change this setting, or the unit will not operate properly or produce[...]

14 f) Freeze Timer (S1 dip switch 9 & 10) The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues. Upon termination of freeze timer, machine initiates the harvest cycle. After 2 consecutive timer terminations, machine will shut down, possibly indicating a problem. The freeze timer is factory adju[...]

15 S2 Dip Switch Setting No. 6 Anti-Slush Control OFF Activated (V er . 1.0) ON Deactivated Control Board P01771-02 k) Harvest Promotion Control (S2 dip switch 2) [Program Ver. 3.1, Ver. 3.2] Do not adjust. This must be left in the factory default position or the unit will not operate properly. It is deactivated on the KMD-410 series. When activate[...]

16 temperature at the end of a harvest cycle is 4K or more and if the temperature at the end of a harvest cycle is 48°F (9°C) or less, the harvest cycle is extended for 30 seconds. If the difference between the temperature at the beginning of a freeze cycle and the minimum temperature after 30 seconds in the freeze cycle is 2.5K or more and less [...]

17 [d] 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 dip switch settings to assure that S1 dip switch 3, 4, 7, 8, 9, & 10 and S2 dip switch 1 through 6 a[...]

18 4. HARVEST CONTROL – THERMISTOR A thermistor (semiconductor) is used as a harvest control sensor, anti-slush sensor, and overfreeze sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the harvest timer or momentarily stop the pump motor during the fr[...]

19 5. FLOAT SWITCH [a] EXPLANATION OF OPERATION The float operates 2 switches within the float switch. The lower switch (black and blue wires) is used for low water safety protection, initiating the freeze cycle refill and terminating the freeze cycle. The upper switch (black and red wires) is used to terminate the freeze cycle refill only. Refill [...]

20 6. 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. [a] EXPLANATION OF OPERATION The bin control is connected to the K1 connector (pins 4 & 5) on the control board. When the bin control is calling for ice (proximity switch closed; [...]

21 7. SWITCHES Two different control switches are used for operation of KMD-410MAH and KMD-410MWH. These switches are referred to as the "control switch" and the "service switch" and are located on the control box. [a] CONTROL SWITCH This switch is used to place the machine into one of three modes: “OFF” (center position), ?[...]

22 III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT[...]

23 2. WIRING DIAGRAM * The magnetic cont actor wiring depends on the contactor model. 428393-01 VC20-1a1b 449000-01 G7L-1A-TUB See above 449000-01 only[...]

24 3. TIMING CHART 9°C 5°C ~Program Ver3.1 THERMISTO R COMPRESSO R ON OFF ON HARVES T CYCLE (AFTER BIN FULL) HARVEST CYCLE POWER SWITCH FREEZE CY CLE FREEZE CY CLE HARVEST CYCLE (INITIAL) ON OFF PART NAME HARVEST CYCLE HARVEST C YCLE (INCLUDING DR AIN) BIN FULL OFF Program Ver3.2 FAN MOTOR ON OFF ON PUMP MOTO R HOT G AS VALVE ON OFF HARVEST WATER[...]

25 4. PERFORMANCE DATA [a] KMD-410MAH WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 70/21 90/32 70/21 415 188 388 176 354 160 80/27 395 179 353 160 320 145 APPROXIMATE ICE PRODUCTION PER 24 HR. 90/32 388 176 324 147 289 131 lbs./day kg./day 100/38 382 173 316 143 257 117 70/21 710 731 753 80/27 726 758 776 APPROXIMATE ELECTRIC CONSUMPTION 90/[...]

26 [b] KMD-410MWH WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 70/21 90/32 70/21 440 200 423 192 392 178 80/27 427 194 401 182 364 165 APPROXIMATE ICE PRODUCTION PER 24 HR. 90/32 423 192 382 173 347 157 lbs./day kg./day 100/38 414 188 373 169 315 143 70/21 670 673 682 80/27 672 677 688 APPROXIMATE ELECTRIC CONSUMPTION 90/32 673 680 690 watts[...]

27 IV. SERVICE DIAGNOSIS 1. 10-MINUTE DIAGNOSTIC PROCEDURE The 10 minute check out procedure is basically a sequence check which c an 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 cond[...]

28 a. Lower Float Switch 1st Activation: Refill – The refill can occur at any time during the freeze cycle (1 refill per cycle). As ice builds the water level drops in the reservoir and the lower float switch activates (opens). LED 5 comes on and the control board energizes the fill water valve. The fill water valve remains energized until the up[...]

29 2. DIAGNOSTIC CHARTS [a] NO ICE PRODUCTION 2. See "II. 6. [b] Bin Control Check Procedur e." 5. See chart [a] [7].[...]

30 1. See "II. 4. Harvest Control - Thermistor." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure."[...]

31 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure."[...]

32 [b] EVAPORATOR IS FROZEN UP 1. Adjust or replace. See "V. 9. Adjustment of Water Re g ulatin g Valve ." 1. See "V. 17. Thermistor." 1. See "II. 3. [c] Controls and Adjustments, b) Harvest Timer." 1. See "II. 3. [d] Control Board Check Procedure."[...]

33 [c] LOW ICE PRODUCTION [d] ABNORMAL ICE a) See chart [b] [1] and check float switch, fill and harvest water valves, control board, water pump, spray tubes, evaporator, and expansi on valve. b) See chart [a] [1] and check dirty air filter or con denser, ambient or water temperature, refrigerant charge, water p ressure, and condenser water regulat[...]

34 [e] OTHER a) See chart [b] [1] & [3] and check float switch, fill and harvest water valves, control board, spray tubes, water system, refrigerant charge, and expansion valve. 1. See "II. 6. [b] Bin Control Check Procedur e." c) Ice Cube Guide, Water Tank, Deflector[...]

35 V. REMOVAL AND REPLACEMENT 1. SERVICE FOR REFRIGERANT LINES [a] SERVICE INFORMATION 1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R404A] The compressor must not be opened more than 15 minutes in replacement or service. Do not mix lubricants of different compressors even if both are charged with the same refrigerant, e[...]

36 7) Evacuation, Vacuum Pump and Refrigerant Charge [R404A] Never allow the oil in the vacuum pump to flow backward. The vacuum level and vacuum pump may be the same as those for the current refrigerants. However, the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for R404A. 8) Refrigerant Lea[...]

37 2. BRAZING Note: All brazing connections inside the bin are clear coated. Sandpaper the brazing connections before unbrazing the components. Use a good abrasive cloth to remove the coating. 3. COMPRESSOR 1) Turn off the power supply. 2) Remove the panels and water tank. See "V. 14. WATER TANK."[...]

38 3) Recover the refrigerant and store it in an approved container. 4) Remove the terminal cover on the compressor and disconnect the compressor wiring. 5) Remove the hold-down bolts, washers, and rubber grommets. 6) Remove the discharge and suction pipes. 7) Remove the compressor. Unpack the new compressor package. 8) Attach the rubber grommets o[...]

39 5) Remove the drier using brazing equipment. 6) Braze the new drier, with the arrow on the drier in the direction of the refrigerant flow. Use nitrogen gas at a pressure of 20 to 30 kPa when brazing tubings. Braze in an access valve using a tee if necessary. 7) Check for leaks using nitrogen gas (970 kPa) and soap bubbles. 8) Evacuate the system[...]

40 8) Install the new drier (see "V. 4. DRIER"). 9) Check for leaks using nitrogen gas (970 kPa) and soap bubbles. 10) Evacuate the system and charge it with refrigerant (see "V. 1. [c] EVACUATION AND RECHARGE"). 11) Attach the solenoid coil to the valve body, and secure it with the screw. 12) Connect the lead wires. 13) Refit t[...]

41 9) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, 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 posit ion on the tube. Be sure to secure the bulb with [...]

42 14) Turn on the power supply. 8. WATER REGULATING VALVE – WATER-COOLED MODEL ONLY 1) Turn off the power supply. 2) Remove the panels. 3) Close the condenser water supply line shut-off valve, then open the condenser water supply line drain valve. 4) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve.[...]

43 17) Check for water leaks. 18) Replace the panels in their correct positions. 19) Turn on the power supply. 9. 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 necess[...]

44 7) Replace the panels in their correct positions. 8) Turn on the power supply. 11. PUMP MOTOR 1) Turn off the power supply. 2) Remove the panels and front insulation. 3) Disconnect the connector of the pump motor lead. 4) Remove the thumbscrew securing the pump motor. 5) Remove the hose band connecting the discharge hose. 6) Slide the pump motor[...]

45 7) Remove the hose band connecting the discharge outlet and pull off the rubber hose. 8) Install the new motor in the reverse order of the removal procedure. 9) Replace the panels and front insulation in their correct positions. 10) Turn on the power supply. 12. WATER VALVE 1) Turn off the power supply. 2) If replacing the harvest and/or fill wa[...]

46 7) Remove the two mounting screws. 8) Install the new valve in the reverse order of the removal procedure. 9) Open the water supply tap. 10) Plug in the icemaker or connect the power source. 11) Check for leaks. 12) Refit the panels in their correct positions. 14. WATER TANK 1) Remove the front panel, then remove the front insulation 2) Loosen t[...]

47 10) Install the new water tank in the reverse order of the removal procedure. 11) Refit the panels in their correct positions. 12) Turn on the power supply. 15. FLOAT SWITCH 1) Remove the pump motor bracket. See "V. 14. WATER TANK." 2) Pull up the pump motor bracket from the water tank. 3) Flip over the pump motor bracket assembly, the[...]

48 4) Install the new float switch in the reverse order of the removal procedure. 5) Refit the panels in their correct positions. 6) Turn on the power supply. 16. BIN CONTROL SWITCH 1) Remove the water tank. See "V. 14. WATER TANK." 2) Disconnect the connector of the bin control switch lead (black). 3) Pull out the bin control switch tab [...]

49 8) Connect the bin control connector to the side of the control box. 9) Replace the water tank, cube guide, pump motor bracket, pump motor and float switch in their correct positions until they snap in place. CAUTION Be sure to let the discharge hose pass behind the copper tube and connect it securely in position. Otherwise, the discharge hose m[...]

50 8) Attach the new thermistor in position on the suction pipe and press down the thermistor holder over the thermistor. Be careful not to damage the thermistor lead. Cover the parts with the insulation and secure them with the ties. Keep the thermistor inside the thermistor holder. After the thermistor holder is fitted, do not pull the thermistor[...]

51 Note: After replacing the components inside the control box, connect and tie the wires properly in their correct position. Especially make sure that the harness does not press the push buttons on the control board. Control Box Cover Control Box Screw Screws Controller Board Control Switch Service Switch Fuse Fuse Holder Starter Transformer Capac[...]

52 [a] CONTROL & SERVICE SWITCH 1) Disconnect the tab terminals and remove the nut securing the power switch. 2) Install the new switch in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [b] FUSE 1) Use a phillips head screwdriver to remove the fuse hold[...]

53 [g] STARTER 1) Disconnect the terminals, remove the mounting screw. 2) Install the new starter in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [h] RUN CAPACITOR 1) Disconnect the terminals on the starter and remove the nut securing the run capacitor. 2[...]

54 6) The spray tube is easily cleanable by removing the black rubber caps on the ends. 7) Remove the hose band connecting the water supply tube. 8) Pull the water supply tube towards you. 9) Remove the top insulation. 10) The spray guide is located under the water supply tube. Pull off the spray guide from the evaporator. 11) Refit the removed par[...]

55 VI. CLEANING AND MAINTENANCE INSTRUCTIONS 1. CLEANING [a] CLEANING PROCEDURE 1) Dilute approximately 9.5 fl. oz. (281 ml) of recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 1.8 gallon (6.8 lit.) of water. 2) Remove all ice from the evaporator and the storage bin/dispenser unit. Note: To remove[...]

56 7) Remove the front panel then remove the front insulation (the large insulation panel in front of the evaporator) by lifting up the panel slightly and pulling it towards you. 8) In bad or severe water conditions, clean the float switch as described below. Otherwise, continue to step 9. a. Loosen the two thumbscrews securing the pump motor brack[...]

57 g. Wipe down the float switch housing, shaft and float with cleaning solution. Rinse the parts thoroughly with clean water. h. Replace the float switch in its correct position. i. Replace the removed parts in the reverse order of which they were removed. 9) Pour the cleaning solution into the water tank. 10) Move the service switch to the "[...]

58 31) Remove the front panel. 32) Repeat steps 18 through 31 three more times to rinse thoroughly. Note: If you do not sanitize the icemaker, go to step 14 in "Sanitizing Procedure." [b] SANITIZING PROCEDURE – FOLLOWING CLEANING PROCEDURE 1) Dilute a 5.25% sodium hypochlorite solution (chlorine bleach) with water (add approximately 0.9[...]

59 [a] STAINLESS STEEL EXTERIOR To prevent corrosion, wipe the exterior occasionally with a clean, soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. [b] STORAGE BIN AND SCOOP * Wash your hands before removing ice. Use the plastic scoop provided (bin accessory). * The storage bin/dispenser unit is for ice us[...]

60 2) Move the control switch on the control box to the "OFF" position. 3) Wait 3 minutes. 4) Move the control switch to the "ICE" position. 5) Replace the front panel in its correct position and turn on the power supply. 6) Allow 5 minutes for the icemaker to fill with water and the water pump to start operating. 7) Close the c[...]

61 4) Turn off the power supply and remove the front panel. 5) Move the control switch to the "OFF" position. 6) Replace the front panel in its correct position. 7) Remove all ice from the storage bin/dispenser unit, and clean the storage bin/dispenser unit. 8) Close the icemaker water supply line drain valve.[...]