Hoshizaki KM-501MAH manual

1 Hoshizaki “A Superior Degree of Reliability” www .hoshizaki.com Models KM-501MAH KM-501MWH KM-501MRH Modular Crescent Cuber Hoshizaki America, Inc. S E RV I C E M A N U A L ™ Number: 73137 Issued: 10-16-2006 Revised: 3-27-2007[...]

2 IMPOR T ANT Only qualified ser vice technicians should attempt to ser vice or maintain this icemaker . No such ser vice or maintenance should be under taken until the technician has thoroughly read this Ser vice Manual. HOSHIZAKI provides this man ual primar ily to assist qualified ser vice technicians in the ser vice and maintenance of the ice[...]

3 Please re vie w this manual. It should be read carefully bef ore the icemak er is ser viced or maintenance operations are perf or med. Only qualified ser vice technicians should ser vice and maintain the icemaker . This manual should be made a v ailab le to the technician prior to ser vice or maintenance. CONTENTS I. Specifications ............[...]

4 III. T echnical Inf or mation ...................................................................................................... 23 A. W ater Circuit and Refr igeration Circuit ........................................................................ 23 1. KM-501MAH (air-cooled) .................................................................[...]

5 AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 13 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day ( kg/day ) 70 *498 (226) 474 (215) 433 (197) Reference without *marks 80 480 (218) 442 (201) 397 (180) 90 474 (215) *416 (1[...]

6 2. KM-501MWH (water-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 10 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs./day [...]

7 3. KM-501MRH (remote air-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 15 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) 50 70 90 lbs.[...]

8 B. Condensing Unit 1. URC-6F 24" (610 mm.) 23-1/32" (585 mm.) 19-11/16" (500 mm.) 18-1/8" (460 mm.) 20-15/32" (520 mm.) 21-15/16" (557 mm.) 7/8" DIA. HOLE (23 mm. DIA.) 6-5/16" (160 mm.) 2-15/16" (75 mm.) 18-1/8" (460 mm.) 6/16" x 3/4" (10 mm. x 20 mm.) 4 x 2 (SLO TTED HOLES) 17-1/8"[...]

9 SPECIFICA TIONS MODEL: URC-6F Galvaniz ed Steel 21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 453.8 mm.) R404A 1 lb . 2 oz. (505 g) Net 61 lbs. (28 kg) Shipping 68 lbs. (31 kg) One Shot Couplings (P ar ker) P er manent Connection Air-cooled Condensing Pressure Regulator Min. -20°F - Max. +122°F (-29°C to +50°C) Outdoor use EXTER[...]

10 II. General Information A. Construction 1. KM-501MAH (air-cooled) Spr a y T ubes W ater Supply Inlet Control Switch Condenser Hot Gas V alve Expansion V alve F an Motor C o n d e n s e r Compressor D r i e r Float Switch Control Bo x W ater Pump Bin Control Ther mostat[...]

11 2. KM-501MWH (water-cooled) Spra y T ubes W ater Supply Inlet Control Switch W ater Regulator Expansion V alve Hot Gas V alve Compressor Float Switch Drier W ater Pump Control Box Bin Control Ther mostat[...]

12 3. KM-501MRH (remote air-cooled) Spra y T ubes W ater Supply Inlet Control Switch Junction Bo x Expansion V alve Receiv er T ank Compressor Float Switch Drier W ater Pump Hot Gas V alv e Line V alve Control Bo x Bin Control Ther mostat[...]

13 B. Sequence of Operation The steps in the sequence are as outlined below . When po wer is supplied, a 5 second dela y occurs at star tup . Note that the order of the LEDs from the outer edge of the board is 1, 4, 3, 2. 1. One Minute Fill Cycle LED 4 is on. WV opens and the fill period begins. After 1 minute, the board chec ks f or a closed F/S.[...]

14 KM-501MAH, KM-501MWH, KM-501MRH Sequence Flow Chart and Component Operation 1. One Minute Fill Cycle 2. Har vest Cycle 3. Freez e Cycle 4. Pump-Out Cycle Cycle Steps WV Energized F/S open F/S closed Comp energized HGV energized FMR energized WV continues Thermistor temp reaches 48°F (9°C) (3.9 k Ω or less) Har v est timer star ts F/S open Com[...]

15 C. Control Boar d • A HOSHIZAKI e xclusiv e solid-state control is emplo yed in KM-501MAH, KM-501MWH and KM-501MRH Modular Crescent Cubers. • All models are pretested and f actor y-adjusted. CA UTION 1. F ragile , handle v er y carefully . 2. A control board contains integrated circuits, which are susceptib le to failure due to static discha[...]

16 Control Boar d P ar t Number 2A1410-01 (f actor y); 2A1410-02 (service) T ype HOS-001A (Control Products - 10 Pin) Contr ol Pr oducts "E" Contr ol Boar d 1. Control Boar d La y out Output T est Switch (used to test rela ys on board) Connector K3 Har v est Control (thermistor) Connector K4 Open (not connected) Microprocessor (board re v[...]

17 2. Features a) Maximum W ater Supply P eriod – 6 minutes Inlet water v alve opening, in the harvest cycle , is limited by the harvest timer . The water v alv e cannot remain open longer than the maximum period. The w ater v alv e can close in less than six minutes if the harvest cycle is completed. b) Harvest Backup Timer and Freeze Timer The [...]

18 f) LED Lights and A udible Alarm Saf eties The red LED indicates proper control v oltage and will remain on unless a control v oltage problem occurs . At star tup a 5 second delay occurs while the board conducts an internal timer check. A shor t beep occurs when the power s witch is tur ned OFF . The green LEDs 1 through 4 energiz e and sequence[...]

19 3. Controls and Adjustments a) Default Dip Switch Settings The dip s witch is f actor y-adjusted to the follo wing positions: Dip Switch No . 1 2 3 4 5 6 7 8 9 10 KM-501MAH OFF ON OFF OFF ON ON OFF OFF ON OFF KM-501MWH OFF OFF OFF OFF ON ON OFF OFF OFF OFF KM-501MRH OFF OFF OFF OFF ON ON OFF OFF OFF OFF F reeze Timer (9 & 10) Pump-Out F requ[...]

20 c) Harvest Timer (dip switch 1 & 2) The har v est timer star ts counting when the ther mistor reads 48°F (9°C) at the e v aporator outlet. No adjustment is required under nor mal use, as the harvest timer is adjusted to the suitable position. How e ver , a setting longer than the factory setting may be advised in cases where the flush pro[...]

21 e) Pump-Out Frequency Contr ol (dip s witch 5 & 6) The pump motor drains the w ater tank at the frequency set b y the pump-out frequency control. The pump-out frequency control is f actor y-adjusted to drain the w ater tank e very 10 cycles, and no adjustment is required. How e v er , where water quality is bad and the icemaker needs a pump [...]

22 4. Control Boar d Chec k Procedure Bef ore replacing a control board that does not sho w a visible def ect and that you suspect is bad, alwa ys conduct the f ollowing chec k procedure. This procedure will help y ou v erify your diagnosis . 1) Check the dip s witch settings to assure that #3, 4, 7, 8, 9, & 10 are in the f actor y def ault pos[...]

23 III. T echnical Inf ormation A. W ater Cir cuit and Refrigeration Circuit 1. KM-501MAH (air-cooled)[...]

24 2. KM-501MWH (water-cooled)[...]

25 3. KM-501MRH (remote air-cooled)[...]

26 B. Wiring Diagrams 1. KM-501MAH (air-cooled) and KM-501MWH (water -cooled) * Pressure Switch Air-Cooled Model W ater-Cooled Model Cut-out 412± 21 PSIG 384± 21 PSIG Cut-in 327±21 PSIG 284±21 PSIG 0 0 *[...]

27 2. KM-501MRH (remote air-cooled) * * Pressure Switch Cut-out 412± 21 PSIG Cut-in 327±21 PSIG 0[...]

28 C. Timing Chart *1 The icemaker does not complete a harvest cycle in the first 2 or 3 min utes. See "II.C .3. Controls and Adjustments."[...]

29 *1 The pump motor waits f or 2 seconds before starting a pump-out drain cycle. See "II.C.3. Controls and Adjustments." *2 The icemaker does not complete a harvest cycle in the first 2 or 3 min utes. See "II.C .3. Controls and Adjustments."[...]

30 70/21 498 226 474 215 433 197 80/27 480 218 442 201 397 180 90/32 474 215 416 189 372 169 lbs./day kg./da y 100/38 463 210 406 184 332 150 70/21 80/27 90/32 watts 100/38 70/21 245 0.93 199 0.75 177 0.67 80/27 210 0.79 139 0.53 139 0.53 90/32 199 0.75 89 0.34 79 0.30 gal./day m 3 /day 100/38 147 0.56 86 0.33 71 0.27 70/21 80/27 90/32 min. 100/38 [...]

31 2. KM-501MWH (water-cooled) Note: 1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used f or ref erence only . 2. W e reser v e the right to make changes in specifications and design without prior notice. 70/21 498 226 495 224 465 211 80/27 496 225 491 223 447 203 90/32 495 224 488 221 449 204 lbs./d[...]

32 3. KM-501MRH (remote air-cooled) Note: 1. Pressure data is recorded at 5 minutes into freezing cycle. The data not in bold should be used f or ref erence only . 2. W e reser v e the right to make changes in specifications and design without prior notice. 70/21 482 219 475 215 437 198 80/27 476 216 465 211 412 187 90/32 475 215 457 207 410 186 l[...]

33 IV . Service Diagnosis A. 10-Minute KM Diagnostic Pr ocedure The 10 minute chec k out procedure is basically a sequence chec k which can be used at unit star t-up or for system diagnosis . Using this check out procedure will allo w y ou to diagnose electrical system and component failures in appro ximately 10 minutes under nor mal operating cond[...]

34 freeze with the float s witch remov ed, replace the board. Note: Nor mal freeze cycle will last 20 to 40 min utes depending on model and conditions. Cycle times and pressures should f ollow perf or mance data provided in this manual. 6) Pump-Out Cycle (10/20 second pump out) – the compressor remains energiz ed, the hot gas v alv e energizes ,[...]

35 Prob lem P ossible Cause Remedy 3. Ambient or condenser water temper ature too warm. 3. Reduce temperature. 4. Refrigerant ov ercharged. 4. Recharge. 5. F an not operating. (e xcept water-cooled model) 5. See char t 1.[6] 6. Refrigerant line or components plugged. 6. Clean and replace drier . 7. Condenser water pressure too low or off . (water-c[...]

36 Prob lem P ossible Cause Remedy m) Interlock Switch Open (Cleaning V alve) 1. Misaligned. 1. Realign. 2. Bad contacts. 2. Check f or continuity and replace. n) W ash Switch 1. W ASH position. 1. Mov e to ICE position. 2. Bad contacts. 2. Check and replace . [2] W ater continues to be supplied, and the icemaker will not star t. a) Float Switch 1.[...]

37 Prob lem P ossible Cause Remedy 2. Clogged. 2. Clean. 3. Pump out check v alv e leaking by . 3. Check assemb ly and clean. d) Pump Motor 1. Motor winding opened. 1. Replace. 2. Bearing wor n out. 2. Replace. 3. Wiring to pump motor . 3. Check f or loose connection or open, and replace. 4. Defectiv e capacitor . 4. Replace. 5. Defectiv e or bound[...]

38 2. Evaporator is Fr ozen Up Prob lem P ossible Cause Remedy [1] F reeze cycle time is too long. a) Float Switch 1. Leads shor t-circuit or def ectiv e s witch. 1. Check and replace . 2. Float does not mov e freely . 2. Clean or replace. b) Inlet Water V alve 1. Diaphragm does not close. 1. Check f or water leaks with icemaker off . c) Control Bo[...]

39 Prob lem P ossible Cause Remedy g) W ater Supply Line 1. T oo small; requires 3/8" OD line dedicated per machine. 1. Increase water line size . h) W ater Filter 1. Flow rate too small. 1. Replace with filter that has larger flow r ate. 3. Low Ice Pr oduction Prob lem P ossible Cause Remedy [1] F reeze cycle time is long. a) See char t 1.[[...]

40 Prob lem P ossible Cause Remedy 2. Mounting pad out of position. 2. Reinstall. d) Refrigerant Lines 1. Rub or touch other lines or surf aces. 1. Replace. [3] Ice in storage bin often melts. a) Drain Line(s) 1. Plugged. 1. Clean. b) Icemaker and Bin 1. Drains not run separately . 1. Separate the drain lines . c) Ice Cube Guide 1. Out of position.[...]

41 V . Remo v al and Replacement of Components IMPOR T ANT Ensure all components, f asteners and thumbscrews are securely in place after the equipment is ser viced. IMPOR T ANT 1. The P oly ol Ester (POE) oils used in R-404A units can absorb moisture quickly . Theref ore it is impor tant to prev ent moisture from enter ing the system when replacing[...]

42 8) If necessar y , add any remaining charge to the system through the lo w-side. Use a throttling v alv e or liquid dispensing de vice to add the remaining liquid charge through the low-side access por t with the unit running. 9) Close the two refrigerant access v alv es , and disconnect the hoses and ser vice manif old. 10) Cap the access v alv[...]

43 4) Remov e the ter minal cov er on the compressor , and disconnect the compressor wiring. 5) Remov e the discharge and suction pipes using brazing equipment. 6) Remov e the hold-down bolts, w ashers and r ubber grommets . 7) Slide and remov e the compressor . Unpack the ne w compressor package. Install the new compressor . 8) Attach the rubber g[...]

44 E. Remov al and Replacement of Expansion V alve IMPOR T ANT Sometimes moisture in the refrigeration circuit e xceeds the drier capacity and freezes up at the e xpansion valv e. Alwa ys install a new drier ev er y time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made. 1)[...]

45 1) T ur n off the power supply . 2) Remov e the panels. 3) Recov er the refr igerant and store it in an appro v ed container . 4) Remov e the screw and the solenoid. 5) Disconnect the hot gas v alv e or line v alv e using brazing equipment. 6) Install the new v alve . CA UTION Alwa ys protect the valv e body by using a damp cloth to pre vent the[...]

46 10) Ev acuate the system, and charge it with refrigerant. For air-cooled and w ater-cooled models, see the nameplate f or the required refr igerant charge . For remote air-cooled models, see the charge label in the machine compar tment. 11) Replace the remov ed par ts in the re verse order of which the y were remov ed. 12) Replace the top insula[...]

47 2) Fiv e minutes after a freez e cycle star ts, confirm that the ther mometer reads 104°F to 115°F (40°C to 46°C). If it does not, rotate the adjustment screw b y using a flat blade screwdriv er until the temperature is in the proper r ange. See Fig. 1. Ne xt, check that the ref erence pressure is in the range indicated in the Head Pressur[...]

48 10) Replace the panels in their correct positions. 11) T ur n on the power supply . K. Remov al and Replacement of Thermistor IMPOR T ANT 1. F ragile , handle v er y carefully . 2. Alwa ys use a recommended sealant (High Ther mal Conductiv e T ype), Model KE4560R TV manuf actured by SHINETSU SILICONE, P ar t Code 60Y000-11, or P ar t Code 4A0683[...]

49 L. Remov al and Replacement of Fan Motor Note: When replacing a fan motor with def ective winding, it is recommended that a ne w capacitor be installed. 1) T ur n off the power supply . 2) Remov e the panels. 3) Remov e the junction box co ver from the remote condenser unit (remote air-cooled model). 4) Remov e the closed end connectors from the[...]

50 7) Remov e the closed end connectors from the pump motor leads. 8) Remov e the screw attaching the pump motor assemb ly to the base, then remo ve the pump motor assembly . 9) Remov e the screw attaching the pump motor to the pump motor brac ket. 10) Remov e the screws attaching the pump housing to the pump motor . Remov e the housing and check t[...]

51 VI. Cleaning and Maintenance Instructions IMPOR T ANT Ensure all components, f asteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. A. Cleaning and Sanitizing Procedures W ARNING 1. HOSHIZAKI recommends cleaning this unit at least once a year . More frequent cleaning, how e v er , ma y be req[...]

52 1. Cleaning Procedure 1) Dilute appro ximately 16 fl. oz. of the recommended cleaner Hoshizaki "Scale A wa y" or "LIME-A-W A Y" (Economics Laborator y , Inc.) with 3 gal. of water . 2) Remov e all ice from the ev aporator and the storage bin. Note: T o remov e cubes on the e v aporator , tur n off the power supply and turn i[...]

53 20) Remov e the front panel, and fully open the cleaning valv e. 21) Mov e the control switch to the "W ASH" position. 22) Replace the front panel in its correct position. 23) T ur n on the power supply to rinse off the cleaning solution. 24) T ur n off the power supply after 5 min utes. 25) Remov e the front panel. 26) Remov e one end[...]

54 2. Storage Bin and Scoop • W ash y our hands bef ore remo ving ice. Use the plastic scoop provided (Accessory). • The storage bin is f or ice use only . Do not store anything else in the bin. • K eep the scoop clean. Clean it by using a neutr al cleaner and rinse thoroughly . • Clean the bin liner by using a neutr al cleaner . Rinse thor[...]

55 2. Remov e the water from the potab le water supply line: 1) Remov e the front panel (except w ater-cooled model). 2) Mov e the control switch on the control bo x to the "OFF" position. 3) W ait 3 minutes . 4) Close the potable w ater supply line shut-off valv e and open the potable water supply line drain v alve . 5) Allow the line to[...]