Hoshizaki KML-200MAE manual

NO.: ISSUED: REVISED: HOSHIZAKI MODULAR CRESCENT CUBER MODEL KML-200MAE KML-200MWE SER VICE MANUAL 73095 FEB. 4, 1998 NOV. 29, 2000[...]

2 FOREWORD IMPORT ANT Only qualified service technicians should attempt to service or maintain this icemaker. No such 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 Care Department Phone: 1-800-233-1940 T[...]

3  Please review this manual. It should be read carefully before the icemaker is serviced or maintenance operations 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 V. REMOVAL AND REPLACEMENT OF COMPONENTS .......................................... 33 1. SERVICE FOR REFRIGERANT LINES .............................................................. 3 3 [a] REFRIGERANT RECOVERY ........................................................................ 3 3 [b] EVACUATION AND RECHARGE ...............................[...]

5 * We reserve the right to make changes in specifications and design without prior notice. I. SPECIFICATIONS 1. KML-200MAE 115/60/1 10.8 A (5 Min. Freeze AT 104° F / WT 80° F) 20A 20A Ambient Water Temp. (°F) Temp. (°F) 50 70 90 70 *250 (113) 240 (109) 220 (100) 80 241 (109) 226 (103) 210 ( 95) 90 230 (104) *214 ( 97) 199 ( 90) 100 218 ( 99) 2[...]

6 * We reserve the right to make changes in specifications and design without prior notice. 2. KML-200MWE Ambient Water Temp. (°F) Temp. (°F) 50 70 90 70 80 90 100 AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMP ACITY MAXIMUM FUSE SIZE APPROX. ICE PRODUCTION PER 24 HR. lbs./day ( kg./day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER C[...]

7 II. GENERAL INFORMA TION 1. CONSTRUCTION [a] KML-200MAE[...]

8 [b] KML-200MWE[...]

9 2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KML-200 Series Modular Crescent Cubers. 2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and high quality control system. 3) All models are pre-tested and factory-adjusted. [b] CONTROLLER BOARD CAUTION 1. F[...]

10 (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 Ther- mistor 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 t[...]

11 Connector K1 Pin #1 thru #10 #1, 9 Magnetic Contactor #2 Hot Gas Valve #3 Line Valve #4 Pump Motor (icemaking) #5 Pump Motor (drain) #6 Water Valve #7, 10 Power (line, Bin Control) #8 Open Dip Switch Defrost Timer, Drain Timer & Drain Counter Connector K5 Float Switch Connector K4 Open (not connected) Connector K3 Defrost Control (Thermistor[...]

12 IMPORTANT 1. Board never accepts defrost completion signal within the first 2 minutes in defrost cycle. 2. Defrost cycle time is limited to 20 minutes even if Defrost Timer does not stop counting. 1. Unit energized and Control Switch to “ICE” position. Water supply cycle starts. 2. After 1 minute, Defrost cycle starts. 5. After the first 5 m[...]

13 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. 10/20 second Drain Timer starts counting. 3. Thermistor reads 48° F. Defrost Timer (adjustable from 1 to 3 minutes) starts counting. IMPORTANT Water Valve openin[...]

14 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. 4. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when Float Switch circuit opens. 3. Defrost Timer stops counting. Defrost cycle is[...]

15 [d] CONTROLS AND ADJUSTMENTS (Alpine/Alpine “C” Board) 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 [...]

16 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 neces- sary, check for resistance between Thermistor leads, and visually [...]

17 3) Drain Timer The Drain Timer is factory-adjusted, and no adjustment is required. SETTING TIME Dip Switch Dip Switch No. 3 No. 4 T1 T2 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 C[...]

18 5) 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 continuously even if the Ice Storage Bin is filled with ice. Setting in the prohibited range might cause sever[...]

19 The unit should start the freeze cycle after 1 minute ± 5 seconds from the resistor connection. 3) Check the Controller Board by using test program of the Controller Board. (i) Disconnect the Connector K1 from the Controller Board. Set the Dip Switch No. 7 and 8 on the Controller Board to the “ON” position, and energize the unit. (ii) The c[...]

20 3. SWITCHES Two control switches are used to control operation in the KML Series Modular Crescent Cubers. These switches are referred to as the “Control Switch” and the “Service Switch.” [a] CONTROL SWITCH The Control Switch is located on the lower left section of the control box when facing the front of the machine. This switch is used [...]

21 III. TECHNICAL INFORMA TION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] KML-200MAE[...]

22 [b] KML-200MWE[...]

23 2. WIRING DIAGRAMS [a] KML-200MAE, KML-200MWE Note: KML-200MAE Pressure Switch Cut-out 384 ± 21.3 PSIG Cut-in 284.5 ± 21.3 PSIG KML-200MWE Pressure Switch Cut-out 355.6 ± 21.3 PSIG Cut-in 256 ± 21.3 PSIG[...]

24 * * 3. TIMING CHART Control Sw. in ICE Bin Thermo- stat ON Pressure Sw. ON Overheat Protect Reset Hi Temp Mid Temp Lo Temp Too Lo Temp Normal Too Hi Temp Lo Water Max. Min. 60 min 5 min Min. Max. Max. 2 min 6 min 6 min Max. 20 min Time Up (60 sec) If Float Sw. is OFF From Defrost Cycle When Control Sw. is turned OFF, Pressure Sw. is OFF, or Ther[...]

25 To Freeze Cycle To Stand-by Cycle (When Control Sw. is turned OFF, Pressure Sw. is OFF, or Thermistor Temp. exceeds t1.) From Freeze Cycle Control Sw. in WASH Max. 20 min *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 fir[...]

26 4. PERFORMANCE DATA [a] KML-200MAE Note: Pressure data is recorded first 5 minutes in freezing cycle. The data without *marks should be used for reference. * We reserve the right to make changes in specifications and design without prior notice. AMBIENT WATER TEMP. ( °F/°C ) TEMP. ( °F/°C ) 50/10 70/21 90/32 70/21 *250 (113) 240 (109) 220 (1[...]

27 [b] KML-200MWE HEAT OF REJECTION FROM CONDENSER 5650 W [AT 90°F (32°C) / WT 70°F (21°C)] HEAT OF REJECTION FROM COMPRESSOR 381 W [AT 90°F (32°C) / WT 70°F (21°C)] WATER FLOW FOR CONDENSER 67 gal./h (17.7 lt./h) [AT 100°F (38°C) / WT 90°F (32°C)] PRESSURE DROP OF COOLING WATER LINE less than 10 PSIG (0.7 bar) APPROXIMATE ICE PRODUCTIO[...]

28 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[...]

29 PROBLEM POSSIBLE CAUSE REMEDY l) Controller Board 1. Defective 1. See “II.2[e] CHECKING CONTROLLER BOARD.” [2] Water a) Float switch 1. Connector disconnected. 1. Place in position. continues to 2. Leads opened or defective 2. Check and replace. be supplied, switch. and the ice- 3. Float does not move freely. 3. Clean or replace. maker will [...]

30 PROBLEM POSSIBLE CAUSE REMEDY [4] Water a) Water Solenoid 1. Diaphragm does not close. 1. Check for water leaks continues to Valve with icemaker off. be supplied in b) Controller Board 1. Defective. 1. See “II.2.[e] CHECKING freeze cycle. CONTROLLER BOARD.” [5] No water a) Water Supply Line 1. Water pressure too low and 1. Check and get come[...]

31 3. LOW ICE PRODUCTION 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. Defect[...]

32 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[...]

33 V . REMOV AL AND REPLACEMENT OF COMPONENTS 1. SERVICE FOR REFRIGERANT LINES [a] REFRIGERANT RECOVERY The icemaker unit is provided with two Refrigerant Access Valves on the low-side and high-side lines. Recover the refrigerant from the Access Valves and store it in an ap- proved container. Do not discharge the refrigerant into the atmosphere. [b[...]

34 2. BRAZING W ARNING 1. Refrigerant R22 itself is not flammable, explosive or poisonous. How- ever, when exposed to an open flame, R22 creates Phosgene gas, hazardous in large amounts. 2. Always recover the refrigerant and store it in an approved container. Do not discharge the refrigerant into the atmosphere. 3. Do not use silver alloy or copper[...]

35 7) Slide and remove the Compressor. Unpack the new Compressor package. Install the new Compressor. 8) Attach the Rubber Grommets of the prior Compressor. 9) Sandpaper the Suction, Discharge and Process Pipes. 10) Place the Compressor in position, and secure it using the Bolts and Washers. 11) Remove plugs from the Suction, Discharge and Process [...]

36 4. REMOV AL 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 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 Dr[...]

37 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 protect the valve body by using a damp cloth to prevent the valve fr[...]

38 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[...]

39 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 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 an[...]

40 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[...]

41 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[...]

42 10. 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 or equivalent. 3. Always use a recommended foam insulation (Non-absorbent Type) or equivalent. 4. [...]

43 10) Secure the insulation using the Plastic Cable Ties. 11) Connect the Thermistor leads through the bushing of the Control Box to the K3 Connector on the Controller Board. Note: Do not cut the leads of the Thermistor while installing it. 12) Replace the Control Box Cover and the panels in their correct positions. 13) Turn on the power supply. 1[...]

44 13. REMOV AL AND REPLACEMENT OF PUMP MOT OR 1) Turn off the power supply. 2) Remove the Front Panel. 3) Remove the three screws and the Float Switch Assembly. 4) Remove the wiring connectors from the Pump Motor leads. 5) Remove the four screws and the Pump Motor. 5) Install the new Pump, and replace the removed parts in the reverse order of whic[...]

45 14. REMOV AL AND REPLACEMENT OF SPRA Y TUBE 1) Turn off the power supply. 2) Remove the Front Panel and the Insulation Panel. 3) Release the Clamps, and disconnect the Rubber Hoses. 4) Remove the Spray Tubes by squeezing the side tabs. 5) Install the new Spray Tubes, and replace the removed parts in the reverse order of which they were removed. [...]

46 1. PREP ARING THE ICEMAKER FOR LONG STORAGE VI. CLEANING AND MAINTENANCE INSTRUCTIONS CAUTION When shutting off the icemaker for an extended time, drain out all water from the water line 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-freez[...]

47 [2] Remove the water from the potable water supply line: 1) Turn off the power supply and remove the Front Panel. 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. See Fig. 4. 5) Allow the line to [...]

48 2. CLEANING 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 individuals and damage to the icemaker, do not use ammonia type cleaners. 3. Always wear liquid-proof gloves for safe handling of the cleaning and saniti[...]

49 11) Replace the Insulation Panel and the Front Panel in their correct positions. 12) Turn on the power supply and start the washing process. 13) Turn off the power supply after 30 minutes. 14) Remove the Front Panel. 15) Move the Service Switch to the “DRAIN” position. 16) Replace the Front Panel and turn on the power supply for 2 minutes. 1[...]

50 3. SANITIZING PROCEDURE - Following Cleaning Procedure 1) Dilute IMS-II Sanitizer or a 5.25% Sodium Hypochlorite solution with water (Add 1.0 fl. oz. to 2 gal. of water). Note: IMS-II Sanitizer, Part #SA0004, is available through your Hoshizaki Dealer. 2) Remove the Insulation Panel. 3) Pour the sanitizing solution into the Water Tank. 4) Move t[...]

51 4. 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[...]