Hoshizaki KM-1300MAH manual

1 NO. AUG. 15, 2004 ISSUED: 73118 HOSHIZAKI MODULAR CRESCENT CUBER MODEL KM-1300MAH KM-1300MWH KM-1300MRH SER VICE MANU AL REVISED:[...]

2 IMPOR T 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 Technical Support Department Phone: 1-800-233-1940 Te[...]

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 IV. SERVICE DIAGNOSIS ........................................................................................... 37 1. NO ICE PRODUCTION ........................................................................................ 37 2. EVAPORATOR IS FROZEN UP .......................................................................... 40 3. LOW ICE PR[...]

5 I. SPECIFICA TIONS 1. KM-1300MAH (Air-cooled) Note: We reserve the right to make changes in specifications and design without prior notice.[...]

6 2a. KM-1300MWH (Water-cooled) Serial No. L00001F to M10155C Note: We reserve the right to make changes in specifications and design without prior notice.[...]

7 2b. KM-1300MWH (Water-cooled) Serial No. M10156D- Note: We reserve the right to make changes in specifications and design without prior notice.[...]

8 3. KM-1300MRH (Remote air-cooled) Note: We reserve the right to make changes in specifications and design without prior notice.[...]

9 4. CONDENSING UNIT URC-12F[...]

10 SPECIFICATIONS MODEL: URC-12F EXTERIOR DIMENSIONS (W x D x H) REFRIGERANT CHARGE URC-12F WEIGHT CONNECTIONS REFRIGERANT ELECTRICAL CONDENSER HEAD PRESSURE CONTROL AMBIENT CONDITION Galvanized steel 35 - 11/16" x 15-11/16" x 21-15/16" (907.2 x 398 x 557.8 mm) R404A 5 lbs. 3 oz. (2350 g) Net 80 lbs. (36 kg) Shipping 87 lbs. (39 kg) [...]

11 II. GENERAL INFORMATION 1. CONSTRUCTION [a] KM-1300MAH (Air-cooled)[...]

12 [b] KM-1300MWH (Water-cooled)[...]

13 [c] KM-1300MRH (Remote air-cooled)[...]

14 2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KM-1300MAH, KM-1300MWH, and KM-1300MRH 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] CONTR[...]

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 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[...]

16 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 [...]

17 (Control Products HOS-001A 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 published [...]

18 [c] SEQUENCE 1st Cycle 1. Unit energized and Control Switch to “ICE” position. Water supply cycle starts. 3. Thermistor reads 48°F. Defrost Timer starts counting. 2. After 1 minute, Defrost cycle starts. 5. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when Float Switch circuit opens. IMPORTANT Board never accept[...]

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. IMPORTANT Water Valve opening is limited to 6 minutes. 3. Thermistor reads 48[...]

20 2nd Cycle and after with no 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. 2. Thermistor reads 48°F. Defrost Timer starts counting. 4. After the first 5 minutes in freeze cycle. Ready to complete freeze cycle when Float Switch circui[...]

21 DIP SWITCH NO. 1 2 3 4 5 6 7 8 9 10 KM-1300MAH OFF OFF O N O N O N O N OFF OFF OFF OFF KM-1300MWH OFF OFF O N OFF O N O N OFF OFF OFF O N KM-1300MRH OFF OFF O N OFF O N O N 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[...]

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 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[...]

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

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 ener- gize 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 [...]

26 III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] KM-1300MAH (Air-cooled)[...]

27 [b] KM-1300MWH (Water-cooled)[...]

28 [c] KM-1300MRH (Remote air-cooled)[...]

29 2. WIRING DIAGRAMS [a] KM-1300MAH (Air-cooled) and KM-1300MWH (Water-cooled) Note: Pressure Switch AIR WATER Cut-out 412±21.3 PSIG Cut-out 384±21.3 PSIG Cut-in 327±21.3 PSIG Cut-in 284±21.3 PSIG[...]

30 [b] KM-1300MRH (Remote air-cooled) Note: Pressure Switch Cut-out 412 ±21.3 PSIG Cut-in 327±21.3 PSIG[...]

31 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.”[...]

32 * 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.”[...]

33 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. 4. PERFORMANCE DATA [a] KM-1300MAH (Air-cooled)[...]

34 Note: P ressure data is recorded at 5 minutes into freezing 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. [b] KM-1300MWH (Water-cooled) Serial # L00001F to M10155C[...]

35 [c] KM-1300MWH (Water-cooled) Serial # M10156D- 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.[...]

36 [d] KM-1300MRH (Remote air-cooled) 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.[...]

37 IV . SER VICE DIA GNOSIS 1. NO ICE PRODUCTION 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. [...]

38 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 t[...]

39 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[...]

40 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][...]

41 PROBLEM POSSIBLE CAUSE REMEDY [1] Small Cube a) Ice Cube Guide 1. Out of position. 1. Place in position. Circulated water falls into bin. b) See chart 1 - [5], and check water supply line, Water Solenoid Valve, water system, Pump Motor or Controller Board. c) Drain Valve 1. Dirty. 1. Clean. [2] Cloudy or a) See chart 2 - [1] and - [3], and check[...]

42 V . REMO V AL AND REPLACEMENT OF COMPONENTS IMPORTANT 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[...]

43 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 recom- mends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used. 6) A liquid[...]

44 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[...]

45 14) Check for leaks using nitrogen gas (140 PSIG) and soap bubbles. 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 Termi[...]

46 5. REMO V AL AND REPLA CEMENT OF EXP ANSION V AL VE IMPORTANT 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 [...]

47 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[...]

48 10) Cut the leads of the Solenoid allowing enough lead length to reconnect using closed end connectors. 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. REMOVAL AND REPLACEMENT OF EVAPORATOR IMPORTANT Alwa[...]

49 8. REMO V AL AND REPLA CEMENT OF W A TER REGULA TING V AL VE - W A TER-COOLED MODEL ONL Y IMPORTANT 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) Re[...]

50 14) Check for water leaks. 15) Replace the panels in their correct positions. 16) 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 necessary, us[...]

51 10. REMO V AL AND REPLA CEMENT OF CONDENSING PRESSURE REGULA T OR (C.P .R.) - REMO TE AIR-COOLED MODEL ONL Y IMPOR T 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 r[...]

52 11. REMO V AL AND REPLA CEMENT OF THERMIST OR IMPOR T ANT 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 recommended foam insulation (Non-absorbent Type) or equivalent.[...]

53 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[...]

54 13. REMO V AL AND REPLA CEMENT 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) In[...]

55 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[...]

56 VI. MAINTENANCE AND CLEANING INSTRUCTIONS 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 IMPORT ANT When shutting off the icemaker for an extended time, drain out all water from the water tank and remove th[...]

57 [2] Remove the water from the potable water supply line: 1) Remove the Front Panel. (Already removed on 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 dr[...]

58 2. CLEANING 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 individuals[...]

59 [a] CLEANING PROCEDURE 1) Dilute 27 fl. oz. of the recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 5 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[...]

60 17) Close the Cleaning Valve. Note: The icemaker will not operate unless the Cleaning Valve is completely closed. 18) Replace the Front Panel in its correct position. 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) Mo[...]

61 4) Replace the Insulation Panel and the Front Panel in their correct positions. Note: Make sure that the Control Switch is in the “WASH” position and the Cleaning Valve is open. 5) Turn on the power supply, and start the sanitizing process. 6) Turn off the power supply after 15 minutes. 7) Remove the Front Panel and if necessary, the Insulat[...]

62 3. MAINTENANCE IMPOR T 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) Stora[...]