Hoshizaki KM-630MAH manual

73114 HOSHIZAKI MODULAR CRESCENT CUBER SER VICE MANU AL KM-630MAH KM-630MWH KM-630MRH MODEL JUNE 23, 2004 NO.: ISSUED:[...]

2 IMPORT ANT Only qualified service technicians should attempt to service or maintain this icemaker. No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. HOSHIZAKI AMERICA, INC. 618 Highway 74 South Peachtree City , GA 30269 Attn: HOSHIZAKI T echnical Support Department Phone: 1-800-233-1940 T[...]

3 CONTENTS I. SPECIFICA TIONS ............................................................................................................ 5 1. KM-630MAH ................................................................................................................ 5 2a. KM-630MWH Serial #L00001D - M20270B .........................................[...]

4 IV . SER VICE DIA GNOSIS ................................................................................................. 41 1. NO ICE PRODUCTION .............................................................................................. 4 1 2. EV APORA T OR IS FROZEN UP ........................................................................[...]

5 I. SPECIFICA TIONS 1. KM-630MAH Note: We reserve the right to make changes in specifications and design without prior notice. A C S UP P LY V O LT A GE 208-230 / 60/ 1 (3 wire w i t h neut ral for 115V ) A M P E RA GE 7. 5 A ( 5 M i n. F reez e A T 104°F / W T 80°F) M INIM UM CIRCUIT A M P A CI T Y 15 A MAX I MU M FU SE SI Z E 1 5 A APPR O X I [...]

6 2a. KM-630MWH Serial #L00001D - M20270B Note: We reserve the right to make changes in specifications and design without prior notice. AC SU PPL Y V O LT AG E AMPER AG E M INIM UM CIRCUIT A M P A CIT Y MAX I MU M FU SE SI Z E APPR O X I MAT E I C E PRO D U C T I O N Ambi e nt W AT ER T EMP. ( ° F) P E R 24 HR . T emp. (°F) 50 70 l bs . / day ( k[...]

7 2b. KM-630MWH Serial #M20301E - A C S UP P LY V O LT A GE 208-230 / 60/ 1 (3 wire w i t h neut ral f or 115V ) A M P E RA GE 6. 5 A ( 5 M i n. F reez e A T 104°F / W T 80°F) M INIM UM CIRCUIT A M P A CI T Y 15 A MAX I MU M FU SE SI Z E 1 5 A APPR O X I MAT E I C E PR OD U CT I ON Amb ie n t W AT ER T EMP. ( ° F) PER 2 4 H R . T e mp .( ° F) 5[...]

8 3. KM-630MRH Note: We reserve the right to make changes in specifications and design without prior notice. A C S UP P LY V O LT A GE 208-230 / 60/ 1 (3 wire w i t h neut ral f or 115V ) A M P E RA GE 6. 5 A ( 5 M i n. F reez e A T 104°F / W T 80°F) M INIM UM CIRCUIT A M P A CI T Y 15 A MAX I MU M FU SE SI Z E 1 5 A APPR O X I MAT E I C E PR OD [...]

9 4. CONDENSER UNIT 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 (SLOTTED HOLES) 17-1/8" (43[...]

10 Galvanized Steel 21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 453.8 mm.) R40 4A 1 lb. 2 oz. (505 g) Net 61 lbs. (28 kg) Shipping 68 lbs. (31 kg) One Shot Couplings (Aeroquip) Permanent Connection Air-cooled Condensing Pressure Regulator Min. -20°F - Max. +122°F (-29°C to +50°C) Outdoor use SPECIFICATIONS EXTERIOR DIMENSIONS (W[...]

11 II. GENERAL INFORMA TION 1. CONSTRUCTION [a] KM-630MAH Spray Tubes Water Supply Inlet Control Switch Condenser Hot Gas Valve Expansion Valve Fan Motor Condenser Compressor Drier Float Switch Control Box Water Pump Bin Control Thermostat (except models with Mechanical Bin Control) Mechanical Bin Control (except models with Thermostat)[...]

12 [b] KM-630MWH Spray Tubes Water Supply Inlet Control Switch Water Regulator Expansion Valve Hot Gas Valve Compressor Float Switch Drier Water Pump Control Box Bin Control Thermostat (except models with Mechanical Bin Control) Mechanical Bin Control (except models with Thermostat)[...]

13 [c] KM-630MRH Spray Tubes Water Supply Inlet Control Switch Junction Box Expansion Valve Receiver Tank Compressor Float Switch Drier Water Pump Hot Gas Valve Line Valve Control Box Bin Control Thermostat (except models with Mechanical Bin Control) Mechanical Bin Control (except models with Thermostat)[...]

14 2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in Modular 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-adjusted. [b] CONTROLLER BOARD CAUTION 1. Fragile, handle [...]

15 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 Evaporator 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 temp[...]

16 The green LED’s 1-4 represent the corresponding relays and energize and sequence 5 seconds from initial start-up 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[...]

17 (Control Products HOS-001A Board) The application switch located between relay X3 & X4 must be set to match the original board application. Place this switch in the ALP position if there is no white wire supplied 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,[...]

18 [c] SEQUENCE 1st Cycle 1. Unit energized and Control Switch to “ICE” position. Water supply cycle starts. 2. After 1 minute, Defrost cycle starts. 3. Thermistor reads 48° F. Defrost Timer starts counting. IMPORTANT Water Valve opening is limited to 6 minutes. & 5. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle[...]

19 2nd Cycle and after with pump drain 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° F. Defrost Timer starts counting. IMPORTANT Water Val[...]

20 IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open. 2nd Cycle and after with no pump drain 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 5 minutes in freeze cycle.[...]

21 [d] CONTROLS AND ADJUSTMENTS The Dip Switch is factory-adjusted to the following positions: FOR MODELS WITH MECHANICAL BIN CONTROL: 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 [...]

22 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[...]

23 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 O N OFF 10 seconds 180 seconds OFF O N 10 seconds 120 seconds O N O N 20 seconds 180 seconds T1: Time to drain the Water Tank T2: Time to restrain defrost completion 4) Drain Cou[...]

24 6) Bin Control MODELS WITH THERMOSTAT 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- i[...]

25 (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. Reconnect a 1.5 k Ω - 3.5 k Ω resistor to the Connector K3 (pins #1 and #2) after the first 2 min[...]

26 3. MECHANICAL BIN CONTROL (THESE INSTRUCTIONS NOT APPLICABLE TO MODELS WITH THERMOSTAT) [a] PROXIMITY SWITCH 1) This machine uses a lever-actuated proximity switch (hereafter called “mechanical bin con- trol”) to control the ice level in the storage bin. [b] EXPLANATION OF OPERATION 1) The startup and shutdown of the ice machine is controlle[...]

27 [c] TROUBLESHOOTING (MECHANICAL BIN CONTROL ONLY) 1) Machine will not start (i) Move dip switch No. 7 to the “OFF” position. If the machine starts up within a few seconds, the bin control is the likely problem. If the machine does not start up, refer to Section “IV. Service Diagnosis” to verify that non-bin control related issues are res[...]

28 III. TECHNICAL INFORMA TION 1. W A TER CIRCUIT AND REFRIGERANT CIRCUIT [a] KM-630MAH[...]

29 [b] KM-630MWH[...]

30 [c] KM-630MRH[...]

31 2. WIRING DIAGRAMS [a1] KM-630MAH (with auxiliary codes L-0, M-0, and M-1) and KM-630MWH (with auxiliary codes L-0, M-0, M-1, and M-2) Note: Pressure Switch MAH MWH Cut-out 4 1 2 PSIG Cut-in 327 ± 21 PSIG + 21 - 0 Cut-out 3 8 4 PSIG Cut-in 284 ± 21 PSIG + 21 - 0[...]

32 [a2] KM-630MAH (with auxiliary codes M-2 and after) and KM-630MWH (with auxiliary codes M-3 and after)[...]

33 U1GMA0179608 Note: Pressure Switch Cut-out 4 1 2 PSIG Cut-in 327 ± 21 PSIG [b1] KM-630MRH (with auxiliary codes L-0, M-0, M-1) + 21 - 0[...]

34 [b2] KM-630MRH (with auxiliary codes M-2 and after)[...]

35 3. TIMING CHART[...]

36[...]

37 4. PERFORMANCE D A T A [a] KM-630MAH Note: Pressure data is recorded at 5 minutes into freeze 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/ 21 600 272 562 255 514 233 80/ 27 571 259 512 232 466 2 11 90/ 32 562 25 5 470 213 42 2 191 lb s./[...]

38 [b1] KM-630MWH Serial #L00001D - M20270B 70/ 21 *619 281 596 2 70 563 256 80/ 27 602 273 566 2 57 533 242 90/ 32 596 270 *5 41 245 507 230 lb s./da y k g ./d a y 100/ 38 589 267 533 2 42 *476 216 70/ 21 80/ 27 90/ 32 w a tts 1 0 0 /3 8 70/ 21 *793 3. 00 865 3. 28 1080 4. 09 80/ 27 848 3. 21 1024 3. 88 1240 4. 69 90/ 32 1150 4. 35 *1040 3. 94 129[...]

39 [b2] KM-630MWH Serial #M20301E - Note: Pressure data is recorded at 5 minutes into freeze cycle. The data without * should be used for reference only. We reserve the right to make changes in specifications and design without prior notice. 70/ 21 *621 282 603 273 563 256 80/ 27 607 275 578 262 532 2 41 90/ 32 603 273 *558 253 51 4 233 lb s./da y [...]

40 [c] KM-630MRH Note: Pressure data is recorded at 5 minutes into freeze 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/ 21 603 274 573 260 531 241 80/ 27 580 263 532 242 491 2 23 90/ 32 573 26 0 499 226 45 7 207 lb s./da y k g ./d a y 100/ 3[...]

41 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 Disconne[...]

42 PROBLEM POSSIBLE CAUSE REMEDY l) Controller Board 1. Defective 1. See “II.2[e] CHECKING CONTROLLER BOARD.” m) Interlock Switch 1. “CLOSED” position. 1. Move to “OPEN” 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[...]

43 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[...]

44 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. Defective. 1. See “II.2[e][...]

45 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. For mechanical bin control see “II. 3. [c]” [2] Abnormal a) Pump Motor 1. Bearings worn out. 1. Replace. noise b) Fan Motor 1. Bearings worn out. 1. Replace. 2. Fan blade[...]

46 V . REMO V 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 servici[...]

47 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 High-side 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 refriger- ant or recla[...]

48 3. REMO V AL AND REPLA CEMENT 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[...]

49 15) Evacuate the system, and charge it with refrigerant. 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. 16) Connect the Terminals, and replace the Terminal Cover in its correct position. 17) Replace the panels in their c[...]

50 4. REMO V AL AND REPLA CEMENT 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 or replacement has been made. 1) Turn off the power supply. 2) Remove the panels. 3) Recover the refrigerant and store it in an approved container. 4) Remove the [...]

51 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 disconnect the Expansion Valve using brazing equipment. 6) Braze the new Expansion Valve, with nitrogen gas flowing at the pressure of 3 - 4 PSIG. W ARNING Always pr[...]

52 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. 3) Recover the refrigerant and store it in an approved container. 4) Remove the screw and the Solenoid. 5) Disconnect t[...]

53 7. REMO V AL AND REPLA CEMENT OF EV APORA T OR IMPORT ANT 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) Turn off the power supply. 2) Remove the panels and the Top Insulation over the Evaporator. 3) Recover the refrigerant [...]

54 8. REMO V AL AND REPLA CEMENT 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) R[...]

55 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[...]

56 10. REMO V AL AND REPLA CEMENT OF CONDENSING PRESSURE REGULA T OR (C.P .R.) - REMO TE 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 re[...]

57 11. REMO V AL AND REPLA CEMENT OF THERMIST OR 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 or equivalent. 3. Always use a recommended foam insulation (Non-absorbent Type) or equivalent.[...]

58 Note: For models with the Liquid Bypass, the Thermistor should be located upstream from the Liquid Bypass outlet, and its end should be 4-3/4" or more away from the outlet. See Fig. 3. Min. 4-3/4" Liquid Bypass Flow 10) Secure the insulation using the Plastic Cable Ties. 11) Connect the Thermistor leads through the bushing of the Contr[...]

59 6) Install the new Fan Motor, and replace the removed parts in the reverse order of which they were removed. 7) Replace the panels in their correct positions. 8) Replace the Junction Box Cover in its correct position (Remote Air-cooled model). 9) Turn on the power supply. 13. REMO V AL AND REPLA CEMENT OF W A TER V AL VE 1) Turn off the power su[...]

60 3) Remove the Base Cover. 4) Drain the Water Tank by removing one end of the Pump Tubing. 5) Replace the removed parts in their correct positions. 6) Disconnect the Pump Suction and Discharge Hoses. 7) Remove the screws and the Pump Motor Bracket. 8) Remove the closed end connectors from the Pump Motor leads. 9) Remove the two screws and the Pum[...]

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

62 [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[...]

63 2. CLEANING AND SANITIZING PR OCEDURES 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 condi- tions. 2. To [...]

64 [a] CLEANING PROCEDURE 1) Dilute 16 fl. oz. of the recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 3 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[...]

65 19) Replace the Front Panel in its correct position. 20) Turn on the power supply to fill the Water Tank with water. 21) Turn off the power supply after 3 minutes. 22) Remove the Front Panel, and fully open the Cleaning Valve. 23) Move the Control Switch to the “Wash” position. 24) Replace the Front Panel in its correct position. 25) Turn on[...]

66 [b] SANITIZING PROCEDURE Following Cleaning Procedure 1) Dilute a 5.25 % Sodium Hypochlorite solution with water (Add 1.5 fl. oz. of sanitizer to 3 gal. of water). 2) Remove the Insulation Panel, if it is in its usual position. 3) Pour the sanitizing solution into the Water Tank. 4) Replace the Insulation Panel and the Front Panel in their corre[...]

67 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[...]