Hoshizaki KM-1301SAH-E manual

Hoshizaki “A Superior Degr ee of Reliability” www .hoshizaki.com Models KM-1301SAH-E KM-1301SWH-E KM-1301SRH-E Stackable Crescent Cuber Hoshizaki America, Inc. SE RV ICE MA NU AL ™ Number: 73181 Issued: 4-12-2011[...]

2 IMPOR T ANT Only quali ed ser vice technicians should inst all, ser vice , and maintain the icemaker . No ser vice or maint enance should be under tak en until the t echnician has thoroughl y read this Ser vice Manual. F ailure t o ser vice and maintain the equipment in accordance with this man ual ma y adver sely af fect saf et y , perf orman[...]

3 CONTENTS Impor tant Saf et y Inf or mation ................................................................................................. 5 I. Specications ...................................................................................................................... 6 A. Icemaker .....................................................[...]

4 III. T echnical Inf or mation ...................................................................................................... 25 A. W ater Cir cuit and R efrigeration Cir cuit ........................................................................ 25 1 . KM-1 30 1SAH-E (air -cooled) ........................................................[...]

5 Impor tant Safety Inf ormation Throughout this man ual, notices appear t o bring your at tention t o situations which could result in death, serious injur y , or damage to the unit. W ARNING Indicates a hazar dous situation which could r esult in death or serious injury . C A UTION Indicates a sit uation which could result in dama ge to the unit.[...]

6 AC SUPPLY VOLTAGE 220-240/50/1 AMPERAGE 11.8 A (5 Min. Freeze AT 109°F /W T 59°F) MINIMUM CIRCUIT AMPACIT Y 20 A MAXIMUM FUSE SIZE 20 A APPROXIMAT E ICE PRODUCTIO N Ambient W AT ER TEMP. (°F) PER 24 HR. Tem p. (°F) 50 70 90 lb./day ( kg/day ) 70 *1114 (505) 1082 (491) 992 (450) Referenc e without *mark s 80 1089 (494) 1039 (471) 924 ( 419) 90[...]

7 AC SUPPLY VOLTAGE 220-240/50/1 AMPERAGE 10.7 A (5 Min. Freeze AT 109°F /W T 59°F) MINIMUM CIRCUIT AMPACIT Y 20 A MAXIMUM FUSE SIZE 20 A APPROXIMAT E ICE PRODUCTIO N Ambient W AT ER TEMP. (°F) PER 24 HR. Tem p. (°F) 50 70 90 lb./day ( kg/day ) 70 *1330 (603) 1304 (591) 1239 (562) Referenc e without *mark s 80 1310 (594) 1269 (576) 1189 (539) 9[...]

8 AC SUPPLY VOLTAGE 220-240/50/1 AMPERAGE 12.3 A (5 Min. Freeze AT 109°F /W T 59°F) MINIMUM CIRCUIT AMPACIT Y 20 A MAXIMUM FUSE SIZE 20 A APPROXIMAT E ICE PRODUCTIO N Ambient W AT ER TEMP. (°F) PER 24 HR. Tem p. (°F) 50 70 90 lb./day ( kg/day ) 70 *1270 (576) 1233 (559) 1160 (526) Referenc e without *mark s 80 1241 (563) 1183 (537) 1100 (499) 9[...]

9 B. Condenser Unit 1 . URC-1 4FE Units: mm [in.] 935 [36-1 3/16] 850 [33-1 5/32] 960 [37 -1 3/16] 907 .2 [35-1 1/1 6] 309 [1 2-3/16] 75 [2-1 5/16] 380 [1 4-15/1 6] 557 .8 [21 -1 5/1 6] 68 [2-1 1/1 6] 380 [1 4-15/1 6] 357 [1 4-1/16] 370 [1 4-9/16] 435 [1 7 -1/8] 460 [1 8-1/8] T OP VIEW FRONT VIEW URC F AN MO T OR CONNECTION 7/8"DIAOPENIN[...]

10 AC SUPPLY VOLTAGE 115/50/1 (Connection to Icemaker) FAN MOTOR 115 V Total 2.6FLA 130W EXTERIOR DIMENSIONS (WxDxH) 35-11/16"×15-11/16"×21-15/16" (907.2×398×557.8 mm) DIMENSIONS INCLUDING LEGS (WxDxH) 37-13/16"×18-1/8"×36-15/16" (960×460×937.8 mm) EXTERIOR FINISH Galvanized Steel WEIGHT Net 80 lb. ( 36 kg ) Sh[...]

11 II. General Inf ormation A. Construction 1 . KM-1 30 1SAH-E (air -cooled) Evapor at or Assembl y Spra y T ubes Inlet W ater V alv e W ater Supply Inlet Hot Gas V alv e Junction Bo x Air -Cooled Condenser Check V alv es Contr ol Bo x Drier T ransf ormer Box Contr ol S witch Ther mostatic Bin C ontrol Compr essor Float S witch W ater P ump Check V[...]

12 2. KM-1 30 1SWH-E (w ater -cooled) Ev aporat or Assembl y Spra y T ubes Inlet W ater V alv e W ater Supply Inlet Hot Gas V alv e Junction Bo x W ater Regulating Va l v e Check V alv es Contr ol Bo x Liquid Line V alv e Drier T ransf ormer Box Contr ol S witch Mechanical Bin Contr ol Compr essor Float S witch W ater P ump Check V alv e (wat er) E[...]

13 3. KM-1 30 1SRH-E (r emote air -cooled) Evapor at or Assembl y Spra y T ubes Inlet W ater V alv e W ater Supply Inlet Hot Gas V alv e Junction Bo xes Receiv er T ank Check V alv es Contr ol Bo x Liquid Line V alv e Drier T ransf ormer Box Contr ol S witch Compr essor Float Switch W ater P ump Check V alv e (wat er) Expansion V alves Low -Side Se[...]

14 B. Sequence of Operation IMPOR T ANT KM-1 30 1SAH-E utiliz es a ther most atic bin control. F or KM-130 1SAH-E operation, the K4 jumper (4A4883G0 1) must be in place on the contr ol board RED K4 connector or the unit will not oper at e . 1 . Sequence Cy c les and Shutdo wn The steps in the sequence ar e as outlined below . When pow er is supplie[...]

15 c) F r eez e Cycle LED 1 is on. Comp and FMR r emain energized, PM ener gizes or remains ener gized depending on har v est pump timer (S4 dip s witch 7) set ting . FM and LL V energiz e. HGV and X1 rela y (auxiliar y code T -0, U-0), X1 0 rela y (auxiliar y code U-1 and later) de-energiz e. For the r st 5 minut es, CB will not accept a signal[...]

16 (2) Mechanic al Bin Contr ol (KM-1 30 1SWH-E, KM-1 30 1SRH-E) WhenmechanicalBCisactiv ated(BCopen),they ellow"BCOPEN"LEDcomeson.  The unit then shuts down as outlined in the t ab le below . Cyc le at Mechanical Bin Control A ctivation Shutdown Fill C ycle 1 5 seconds aft er activation. Har v[...]

17 2. Sequence Flow Chart F/S check 1 to 3-min. timer in control (S4 dip switch 1 & 2) Components Energized when the Contr ol S witch is in the "W A SH" P osition The"W ASH"positiononthecontrols witchisusedwhencleaningandsanitizingtheunit. W heninthe"W ASH"po[...]

18 C. Control Boar d • A Hoshizaki e x clusive solid-st at e contr ol boar d is emplo yed in Hoshizaki Stac kab le Crescent Cuber s. • All models are pr etest ed and f actor y set. C A UTION 1 . The control boar d is fragile; handle very carefull y . 2. The control board cont ains int egr at ed cir cuits, which ar e susceptible t o f ailu[...]

19 1 . Contr ol Boar d Lay out "G" Control Boar d P ar t Number 2A3792-0 1 "G" Contr ol Boar d • "ALARM RESET" But ton • "OUTPUT TEST" But ton (used to t est r ela ys on contr ol board) • WHITE K3 Connector Har v est Contr ol (thermistor) • RED K4 Connector K4 Jumper (4A4883G0 1) f or Thermostatic Bin[...]

20 a) LED Lights and Audible Alarm Saf eties At star tup , a 5-second delay occur s while the control boar d conducts an int er nal timer check.  Abeepoccurswhenthecontr olswitchismo vedt othe"ICE"position.  The red LED indicat es proper contr ol v oltage and remains on unless a contr ol v oltage [...]

21 2. Controls and Adjustments C A UTION Dip s witches ar e f actor y set. F ailure t o maintain f actory set tings ma y adver sel y af fect perf or mance and warr anty cov erage . F or mor e inf ormation, contact Hoshizaki T echnical Suppor t at 1 -800-233-1 940. a) Default Dip S witch Set tings The dip s witches ar e f actor y set t o the f ollow[...]

22 c) Pump-Out Timer (S4 dip switch 3 & 4) C A UTION Do not adjust S4 dip s witch 3 of f and S4 dip s witch 4 on f or this model. Otherwise, pump mot or does not rotat e in the pump-out direction. When a pump-out is called f or , the pump motor st ops af t er the pr eceding freez e cycle . The pump motor r estar ts 2 seconds later in the r e ve[...]

23 e) Harvest P ump Timer (S4 dip switch 7) C A UTION F actory set for pr oper operation. Do not adjust. Adjustment outside of the f act or y def ault set ting ma y result in damage t o the icemak er . Depending on the har v est pump timer set ting, the pump mot or energizes and runs the last 0 or 50 seconds of har v est. W hen the pump is on, w at[...]

24 h) Float S witch Contr ol (S5 dip s witch 1) C A UTION Do not adjust. This must be lef t in the f actor y def ault position or the unit will not operat e corr ectl y . F actory set. S5 dip s witch 1 allows f or single or double  oat s witch applications. The KM-1 30 1SAH-E, KM1 30 1SWH-E, and KM-1 30 1SRH-E use a single oat s witch. i) Re?[...]

25 III. T echnical Infor mation A. W at er Cir cuit and R efr igeration Cir cuit 1 . KM-1 30 1SAH-E (air -cooled) W at er Supply Float Switch Drain Check V alv e Expansion V alv es Compr essor Hot Gas Va l v e Check V alv es High-P ressure Switch Strainer Drier Condenser Evapor ator Ser vice Va l v e Discharge Line Suction Line W at er P ump Thermi[...]

26 2. KM-1 30 1SWH-E (w ater -cooled) W at er Supply Float Switch Drain Check V alv e Expansion V alv es Compr essor Hot Gas Va l v e Check V alv es High-P ressure Switch Strainer Drier Condenser Evapor ator Ser vice Va l v e Discharge Line Suction Line W at er P ump Thermistor Spra y T ubes Inlet W ater V alv e Pump-Out W at er T ank Ser vice Va l[...]

27 3. KM-1 30 1SRH-E (r emote air -cooled) W at er Supply Float Switch Drain Check V alv e Expansion V alv es Compr essor Hot Gas Va l v e Check V alv es High-P ressure Switch Strainer Drier Remot e Condenser Unit Evapor ator Ser vice Va l v e Discharge Line Suction Line W at er P ump Thermistor Spra y T ubes Inlet W ater V alv e F reeze/Harvest Pu[...]

28 B. W iring Diagr ams 1 . Auxiliary Code T -0, U-0 a) KM-1 30 1SAH-E (air -cooled) A uxiliar y C ode T -0, U-0 T ransformer Output 1 0.5V at 1 15V * * High-Pr essure Switc h Cut-out 41 2± 21 PSIG Cut-in 327±21 PSIG 0[...]

29 2. Auxiliary Code U-1 and Later a) KM-1 30 1SAH-E (air -cooled) A uxiliar y C ode U-1 and Lat er T ransformer Output 1 0.5V at 1 15V * * High-Pr essure Switc h Cut-out 41 2± 21 PSIG Cut-in 327±21 PSIG 0 Auxiliary Code U-1 and V -0[...]

30 b) KM-1 30 1SWH-E (water -cooled) * T ransformer Output 1 0.5V at 1 15V * High-Pr essure Switc h Cut-out 384± 21 PSIG Cut-in 284±21 PSIG 0[...]

31 c) KM-1 30 1SRH-E (remote air -cooled) * T ransformer Output 1 0.5V at 1 15V * High-Pr essure Switc h Cut-out 41 2± 21 PSIG Cut-in 327±21 PSIG 0[...]

32 C. P erf ormance Data 1 . KM-1 30 1SAH-E (air -cooled) Note: 1 . P r essur e data is r ecor ded at 5 minut es into fr eezing cy cle. The data not in bold should be used f or r ef erence onl y . 2. W e r eserve the right to mak e changes in specications and design without prior notice. 70/21 1114 505 1082 491 992 450 80/27 1089 494 1039 471 92[...]

33 2. KM-1 30 1SWH-E (w ater -cooled) Note: 1 . P r essur e data is r ecor ded at 5 minut es into fr eezing cy cle. The data not in bold should be used f or r ef erence onl y . 2. W e r eserve the right to mak e changes in specications and design without prior notice. 70/21 1330 603 1304 591 1239 562 80/27 1310 594 1269 576 1189 539 90/32 1304 5[...]

34 Note: 1 . P r essur e data is r ecor ded at 5 minut es into fr eezing cy cle. The data not in bold should be used f or r ef erence onl y . 2. W e r eserve the right to mak e changes in specications and design without prior notice. 3. KM-1 30 1SRH-E (r emote air -cooled) 70/21 1270 576 1233 559 1160 526 80/27 1241 563 1183 537 1100 499 90/32 1[...]

35 IV . Service Diagnosis W ARNING 1 . This unit should be diagnosed and repair ed only b y quali ed ser vice personnel t o reduce the risk of death, electr ic shoc k, serious injur y , or re . 2. Risk of electr ic shock. Use e xtreme caution and e x ercise saf e electr ical practices . 3. Moving par ts (e.g ., f an blade) can crush and cut. [...]

36 4) Initial Harvest Cy c le – LEDs 1, 4, and 2 are on. WV and X2 rela y (auxiliar y code T -0, U-0), X1 1 rela y (auxiliar y code U-1 and later) r emain ener giz ed, HGV , X1 rela y (auxiliar y code T -0, U-0), X1 0 rela y (auxiliar y code U-1 and later), Comp , and FMR energiz e. CBmonitorsthew ar mingoftheev aporat orv[...]

37 an inoperativ e Comp , or an inoperative HM. If the unit s witches out of fr eeze with F/S connector r emov ed, b ut would pr eviousl y not switch out of fr eez e with F/S connect ed (longfreez e-3beepalar m),F/Smaybestic king.  T ocheckandcleanF/S ,see"IV .D .  FloatS witchChec ka[...]

38 8) Shutdown a) Thermostatic Bin Contr ol: KM-1 30 1SAH-E When the unit is running hold ice in contact with the thermostatic bulb , the ther mostatic BC s witch opens within 1 0 seconds, shut ting down the unit (CB red"PO WEROK"LEDisof f).  Thebincontrolisf actor yset,andgener ally no adjustment[...]

39 B. Control Boar d Check Bef or e r eplacing a contr ol boar d that does not show a visib le defect and that y ou suspect is bad, alw ay s conduct the follo wing chec k pr ocedur e. This procedur e will help you v erify your diagnosis . Alar mR eset: Ifthecontrolboar disinalar m(beeping),pr essthe"ALARM[...]

40 C. Bin Control Chec k 1 . Thermostatic Bin Contr ol Check: KM-1 30 1SAH-E T o check the thermostatic bin control, f ollow the st eps below . C A UTION When the ambient t emperature is belo w 45°F (7°C), the ther mostatic bin control s witch opens and shuts down the icemak er ev en if the ice storage bin is empty . W hen the ther mostat is set [...]

41 7) P r ess the actuat or paddle, chec k for contin uity across the wir es of the r ed connector . When the actuat or paddle is engaged, the mechanical bin contr ol s witch is open. If closed, check that the actuat or paddle is not restricted. Clean if necessar y . See "IV .C.2.b)MechanicalBinC ontrolCleaning ."Ifthe?[...]

42 b) Mechanical Bin Contr ol Cleaning Scale ma y b uild up on the mechanical bin contr ol. Scale can cause the actuator paddle and magnet to stic k. In this case, the mechanical bin contr ol should be cleaned. W ARNING CHOKING HAZARD: Ensure all components , fast eners, and thumbscr ews ar e securel y in place af t er the unit is ser viced. Make s[...]

43 D . Float S witch Check and Cleaning The  oat s witch is used to det ermine that there is suf ficient wat er in the tank af ter the 1 -minute  ll cy cle and af ter each harvest c y cle. The  oat s witch is also used to det ermine that the appropriat e v olume of w at er has been con v er ted int o ice befor e switching out of the freez [...]

44 2. Float Switc h Cleaning Depending on local wat er conditions, scale ma y b uild up on the  oat switch. Scale on the s witch can cause the  oat to stic k. In this case, the  oat switch should be cleaned. 1) T ur n of f the po wer suppl y . 2)Remo vethefr ontpanel,thenmo v ethecontr ols witchtothe&quo[...]

45 E. Thermist or Chec k T o check thermistor resist ance , f ollow the steps belo w . 1) T ur n of f the po wer suppl y . 2)Remo vethefr ontpanel,thenmo v ethecontr ols witchtothe"OFF"position. 3) Remo ve the contr ol bo x cov er . 4) Remo ve the thermistor . 5) Immerse the thermistor sensor por tio[...]

46 G. Diagnostic Charts Bef or e consulting the diagnostic char ts, chec k for corr ect installation, proper v oltage per unit nameplate ,andadequatewat ersupply . CheckCBusingthestepsin"IV .B. Contr olBoar d Check."Chec kthedipswitchset tingstoassurethatS4dips wit[...]

47 No Ice Pr oduction - Possib le Cause 14 . Float Switch See"IV .D . FloatS witchCheck andCleaning." a) Float does not mov e freely . b) Def ectiv e. 15 . Compr essor a) Compr essor r ela y/magnetic contact or contacts bad or coil winding open. b) Star t capacit or or run capacitor def ectiv e . c) Internal ov erload pr[...]

48 2. F reeze Up Defrostandcleantheunitpriort odiagnosingfr eezeup . See"VI.A. CleaningandSanitizing Instructions." F reeze Up - P ossible Cause Harvest Cy cle 1. Ev aporat or a) Scaled up . b) Damaged. 2. Separator s a) Out of position. 3. Cube Guide a) Out of position. 4. Spray T ubes and/or [...]

49 F reeze Up - P ossible Cause F reeze Cyc le 1. Ev aporat or a) Scaled up . b) Damaged. 2. Separator s a) Out of position. 3. Spray T ubes and/or Spra y Guides a) Dir ty . b) Out of position. 4. Refrigerant charge . a) L o w. 5. Check V alv e a) Defectiv e. 6. Control Boar d See "IV .B. ControlBoar dCheck." a) F reeze timer set[...]

50 3. Low Ice P r oduction Low Ice P r oduction - P ossible Cause Long Harvest Cy cle 1. Evapor at or a) Scaled up . 2. Spray T ubes and/or Spra y Guides a) Dir ty . b) Out of position. 3. Refrigerant Charge a) L o w. 4. Wat er Supply a) Low w ater pr essure. b) External wat er lt ers clogged. c) Insuf ficient w ater line size . Minimum3/8&qu[...]

51 V . R eplacement of Components W ARNING 1 . This unit should be diagnosed and repair ed only b y quali ed ser vice personnel t o reduce the risk of death, electr ic shoc k, serious injur y , or re . 2. Mov ethecontr ols witcht othe"OFF"positionandturnof fthepow ersuppl y bef or e ser v[...]

52 2. Brazing W ARNING 1 . R-404A itself is not  ammab le at atmospheric pressur e and temperatur es up to 1 7 6°F (80°C). 2. R-404A itself is not explosiv e or poisonous. Howe ver , when exposed t o high temper atur es (open  ames), R-404A can be decomposed to f or m h y dr ouoric acid and carbonyl uoride both of which are hazar dous[...]

53 4) Close the low -side val v e and high-side val v e on the g auge manif old. 5) Disconnect the gauge manif old hose from the v acuum pump and at tach it t o a refrigerant service cylinder . Remember t o loosen the connection and purge the air from the hose . For air -cooled and wat er -cooled models, see the nameplat e for the requir ed refrige[...]

54 B. Impor tant Not es f or Component R eplacement C A UTION When r eplacing a component listed belo w , see the notes t o help ensur e pr oper operation. Component Notes Compr essor Install a ne w star t capacit or , run capacitor , and star t rela y . Expansion V alve • At tachtheexpansionv alv ebulbt othesuctionline[...]

55 VI. Cleaning and Maintenance This icemaker m ust be cleaned and maintained in accor dance with the documentation and labels pro vided with the icemaker . Consult with your local distrib ut or about cleaning and maintenance service. T o obtain the name and phone number of y our local distr ib ut or , contact y our near est Hoshizaki Ser vice of f[...]

56 5) Remo ve the drain plug locat ed on the lower fr ont par t of the ice chut e. See F ig . 6. Allow the wat er tank to dr ain. 6) Replace the dr ain plug in its corr ect position. Be careful not t o cr oss thr ead it. 7) In bad or se v ere wat er conditions, clean the  oat s witch assembl y as described below . Otherwise, contin ue t o st ep [...]

57 1 5)Mov ethecontr ols witchtothe"ICE"position. 1 6) Replace the fr ont panel in its corr ect position. 1 7) T ur n on the pow er suppl y t o  ll the wat er tank with wat er . 1 8) T ur n of f the power suppl y af t er 3 minut es. 1 9) Remo v e the fr ont panel. 20)Mov ethecontrols witchtothe[...]

58 B. Maintenance The maintenance schedule belo w is a guideline. More frequent maint enance may be requir ed depending on wat er quality , the icemak er's en vir onment, and local sanitation regulations . W ARNING 1 . Ex cept as specied belo w , only quali ed ser vice technicians should at tempt to service this icemaker . 2. Mov e[...]

59 3) Close the icemaker w ater suppl y line shut-of f val ve , then open the icemak er wat er supply line dr ain v alv e. 4) Allow the line t o drain by gr a vity . 5) At tach a compressed air or carbon dio xide supply t o the icemaker wat er supply line drain v alv e . 6)Mov ethecontrols witchtothe"ICE"position. [...]