Hoshizaki KM-2500SWH3 manual

Hoshizaki “A Superior Degr ee of Reliability” www .hoshizaki.com Models KM-2500SWH3 KM-2500SRH3 Stackable Crescent Cuber Hoshizaki America, Inc. Number: 73164 Issued: 6-10-2010 S E RV I C E M A N U A L ™[...]

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 accor dance with this manual ma y adv ersel y af f ect saf ety , performan[...]

3 IMPOR T ANT This manual should be r ead car efull y bef ore the icemak er is ser viced or maintenance oper ations ar e perf or med. Only quali ed ser vice technicians should install, service, and maint ain the icemak er . Read the w ar nings contained in this booklet carefull y as they giv e impor tant inf or mation reg arding saf et y . Pleas[...]

4 D . Bin Contr ol .................................................................................................................. 22 E. Float Switch ................................................................................................................. 22 F . Ther mist or ...............................................................[...]

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 I. Specications A. Icemaker 1 . KM-250 0SWH3 (w ater -cooled) Note: We r eser v e the r ight t o make changes in specications and design without prior notice. AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 14.2 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 30 A MAXIMUM FUSE SIZE 30 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP[...]

7 2. KM-250 0SRH3 (remote air -cooled) Note: We r eser v e the r ight t o make changes in specications and design without prior notice. AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 17.7 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 30 A MAXIMUM FUSE SIZE 30 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F[...]

8 B. Condenser Unit 1 . URC-23F Note: We r eser v e the r ight t o make changes in specications and design without prior notice. Unit: mm (inches)[...]

9 SPECIFIC A TIONS MODEL: URC-23F AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR 115 V Total 2.6FLA 130W EXTERIOR DIMENSIONS (WxDxH) 46-3/8" x 15-11/16" x 25-15/16" (1178 x 398 x 659 mm) DIMENSIONS INCLUDING LEGS (WxDxH) 48-7/16" x 18-1/8" x 40-7/8" (1230 x 460 x 1039 mm) EXTERIOR FINISH Galvanized Steel[...]

1 0 II. General Inf ormation A. Construction 1 . KM-250 0SWH3 (w ater -cooled) Main T ransformer Bo x Evapor ator Assembly Spra y T ubes Inlet W ater V alv e W at er Supply Inlet Hot Gas V alve Junction Bo x W at er Regulating V alv e Ser vice V alv es Contr ol Bo x Liquid Line V alve Drier Contr ol S witch Bin Contr ol Ther mostat Compr essor Clea[...]

1 1 2. KM-250 0SRH3 (remote air -cooled) Evapor ator Assembly Spra y T ubes Inlet W ater V alv e W at er Supply Inlet Hot Gas V alve Junction Bo xes Receiv er T ank Ser vice V alv es Contr ol Bo x Liquid Line V alve Drier Main T ransformer Bo x Contr ol S witch Bin Contr ol Ther mostat Compr essor Cleaning V alve Float Switch W at er P ump Check V [...]

1 2 B. Sequence of Operation 1 . Sequence Cy c les and Shutdo wn The steps in the sequence ar e as outlined below . When pow er is supplied and BC is closed, CB red "PO WER OK" LED comes on. Ther e is a 5-second dela y befor e star tup. Note that the or der of the LEDs from the out er edge of CB is 1, 4, 3, 2. a) 1 -Minute F ill Cycle LED[...]

1 3 e) Harvest Cy cle Same as the initial harvest cy cle. See "II.B.1 .b) Initial Har v est C y cle ." Note: Unit continues t o cy cle until BC is satis ed or power is turned of f . The unit alw a ys rest ar ts at the 1 -minute  ll cy cle. f) Shutdown When ice cont acts the thermostatic bulb (BC s witch open), BC shuts down the unit[...]

1 4 2. Sequence Flow Chart "E" Contr ol Boar d Sequence Flo w Char t KM-250 0SWH3, KM-250 0SRH3 Startup begins here af ter 5-sec. delay 4. Pump-Out Cyc le • F actor y set f or e v ery cycle (S4 dip s witch 5 & 6) • P ump motor st ops for 2 sec., then re verses for 1 0/20 sec. (S4 dip switch 3 & 4) F/S Check Components Energize[...]

1 5 C. Control Boar d • A Hoshizaki e x clusive contr ol board is emplo yed in KM-2500SWH3 and KM-2500SRH3 Stac k ab le Cr escent Cuber s. • All models are pr etest ed and f actor y -adjusted. • F or a contr ol boar d chec k pr ocedur e, see "IV .B. Contr ol Boar d Chec k." C A UTION 1 . The control boar d is fragile; handle very ca[...]

1 6 "E" Contr ol Boar d 1 . Contr ol Boar d Lay out "E" Control Boar d P ar t Number 2A1 41 0-0 1 (f act or y); 2A1 41 0-02 (ser vice) • "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 Open (not connected) • Micropr ocessor[...]

1 7 2. Feat ures a) Maximum W ater Supply P er iod – 6 minutes The inlet wat er val v e remains energiz ed dur ing har v est f or 6 minutes or the length of har v est whiche ver is shor t er . b) Harvest B ackup Timer and F reez e T imer The har v est bac kup timer shuts down the icemak er if, f or t wo cy cles in a r o w , the har vest cy cle ta[...]

1 8 3. LED Lights and Audib le 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 po wer is tur ned of f. The red LED indicat es proper contr ol v oltage and r emains on unless a control v oltage pr oblem occur s. The gr een LEDs 1 through 4 ener gize and sequence f[...]

1 9 4. 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 -adjusted t o the [...]

20 c) Pump-Out Timer (S4 dip switch 3 & 4) 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 ener gizes 2 seconds lat er in the r e v erse dir ection, taking w at er fr om the bot tom of the tank and f orcing pr essure ag ainst the chec k v al v e seat allo wing wat er to go thr ough th[...]

21 e) Bin Control Select or (S4 dip s witch 7) S4 dip s witch 7 is the bin contr ol select or . C A UTION Do not adjust. This dip switch must be lef t in the fact or y default position or this unit will not operat e corr ectl y . F actory set for pr oper operation. Do not adjust. W hen set t o the on position on a unit with a ther mostatic bin cont[...]

22 D . Bin Contr ol 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 in the pr ohibited range , the icemaker operat es continuousl y ev en if the ice storage bin is  lled with ice. Setting i[...]

23 III. T echnical Inf or mation A. W at er Cir cuit and R efr igeration Cir cuit 1 . KM-250 0SWH3 (w ater -cooled) W at er Supply Cleaning V alve Float Switch Drain Check V alv e Expansion V alves Compr essor Hot Gas V alv e Check V alv es High-P ressure Switch Strainer W at er Regulating V alv e Drier Condenser Evapor ator Ser vice V alv e Discha[...]

24 2. KM-250 0SRH3 (remote air -cooled) W at er Supply Cleaning V alve Float Switch Drain Check V alv e Expansion V alves Compr essor Hot Gas V alv e Check V alv es High-P ressure Switch Strainer Drier Condenser Evapor ator Ser vice V alv e Discharge Line Suction Line W at er P ump Thermistor Spra y T ubes Inlet W ater V alv e F reeze P ump-Out W a[...]

25 B. Wir ing Diagr ams 1 . KM-250 0SWH3 (w ater -cooled), KM-250 0SRH3 (remot e air -cooled) * High Pr essure S witch W ater -Cooled Model R emote Model Cut-out 384± 21 PSIG 41 2± 21 PSIG Cut-in 284±21 PSIG 327±21 PSIG 0 0 * T ransformer Output 1 0.5V at 1 15V[...]

26 C. P erf ormance Data 1 . KM-250 0SWH3 (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 2408 1092 2395 1087 2256 1024 80/27 2398 1088 2379 [...]

27 2. KM-250 0SRH3 (remote 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 2424 1100 2373 1076 2196 996 80/27 2385 1082 2306 1046 2069 939 90/32 [...]

28 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. [...]

29 4) Initial Harvest Cy c le – LEDs 1, 4, and 2 are on. WV remains ener giz ed. Comp , FMR, and HGV energiz e. WV is ener gized during har vest f or a maximum of six minut es or the length of har v est which e ver is shor t er . LED 4 goes off when WV de-energizes . CBmonitor s the war ming of the e vapor at or via the ther mist or locat ed o[...]

30 6) Pump-Out Cy cle (1 0/20 second pump out) – LEDs 1, 3, and 2 are on. LED 4 is on when S4 dip s witch 3 & 4 ar e set t o 3 of f and 4 on. Comp and FMR r emain energized, HGV energiz es. WV ener gizes if S4 dip s witch 3 off & 4 on. LL V de-ener gizes . PM stops f or 2 seconds , then r e ver ses f or 1 0/20 seconds depending on pump-ou[...]

31 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 contr ol boar d is in alar m (beeping), pr ess the "ALARM RESET" but ton on the[...]

32 C. Bin Control Chec k 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 bin control ther mostat operat es t o st op the icemak er e ven if the ice st orage bin is empty . When the ther mostat is set in the pr ohibited range , the icemak er operat es continuously[...]

33 8) Reconnect the b lack  oat switch connect or , then replace the contr ol bo x co v er in its correct position. 9) Mov e the control s witch to the "ICE" position. Replace the insulation panel and the front panel in their corr ect positions, then tur n on the po wer suppl y . Af t er 1 minut e, the 1 -minute  ll cy cle should en[...]

34 7) Wipe do wn the  oat switch assemb l y's housing , shaf t,  oat, and r etainer r od with a mixture of 1 part Hoshizaki "Scale A wa y" and 25 par ts war m wat er . Clean the inside of the rubber boot and hose with the cleaning solution. Rinse the par ts thoroughl y with clean wat er . 8) Reassemb le the oat s witch assem[...]

35 F . Diagnostic Charts 1 . No Ice P r oduction Pr oblem P ossible Cause Remed y [1] The icemaker will not star t. a) P o wer Suppl y 1 . Of f, b lown fuse , or tripped break er . 1 . T ur n on, r eplace, or r eset. 2. Loose connection. 2. Tight en. 3. Bad contacts . 3. Check f or continuit y and replace . 4. Not within specications. 4. Ref er [...]

36 Pr oblem P ossible Cause Remed y [1] The icemaker will not star t. (continued) h) Control T ransf or mer 1 . Coil winding open or shor ted. 1 . Replace. i) Wiring to C ontrol Board 1 . Loose connections or open. 1 . Chec k f or continuity and replace . j) Interloc k Switch (Cleaning V alv e) 1 . Open position. 1 . Mo v e t o closed position. 2. [...]

37 Pr oblem P ossible Cause Remed y [3] Compressor will not star t or st ops operating . (continued) c) Internal Overload P rot ect or Open (check 1 through 3 t o the r ight and d through f belo w) 1 . Loose t erminal. 1 . Tight en or replace. 2. V oltage. 2. Check and corr ect. 3. Dir ty condenser . 3. Clean. d) Star ter 1 . Bad cont acts. 1 . Che[...]

38 Pr oblem P ossible Cause Remed y [7] F an mot or will not star t, or is not operating (e xcept wat er -cooled model). (continued) b) Control Boar d 1 . Def ective. 1 . See "IV .B. Contr ol Board Check." [8] All components run, but no ice is produced. a) Refrigerant 1 . Low char ge. 1 . Check f or leaks. Recov er , repair , ev acuat e, [...]

39 Pr oblem P ossible Cause Remed y [1] F reez e cy cle time is too long . (continued) h) Expansion V alv e 1 . Bulb loose. 1 . Secure bulb . 2. Operating erraticall y . 2. Check and r eplace . i) Contr ol Boar d 1 . Def ectiv e. 1 . See "IV .B. Contr ol Boar d Check." [2] All ice formed on e v aporat or does not f all into bin in harvest[...]

40 Pr oblem P ossible Cause Remed y [3] Other . a) Ice Cube Guide 1 . Out of position. 1 . Place in position. b) Bin Contr ol Ther mostat 1 . Bulb out of position. 1 . Place in position. 2. Bad contacts . 2. Check f or continuit y and replace . 3. Low Ice P r oduction Pr oblem P ossible Cause Remed y [1] F r eeze c ycle time is long. a) Inlet W ate[...]

41 Pr oblem P ossible Cause Remed y [2] Har vest c y cle time is long. a) Wat er Supply 1 . W ater t emperatur e t oo cold. 1 . Incr ease temper atur e. b) Ther mistor 1 . Out of position or def ectiv e. 1 . R eat tatch and secure. See "IV .E. Ther mistor Chec k." c) Contr ol Boar d 1 . Not reading thermistor . 1 . Chec k and replace . 2.[...]

42 [2] Cloudy or irregular cubes. a) Evapor at or 1 . F rozen up . 1 . See "IV .F .2. Evaporat or is F rozen Up ." 2. Scaled up . 2. Clean 3. D amaged. 3. Replace . b) W ater Sy stem 1 . W ater suppl y line too small; requir es 1/2" nominal line dedicated per machine. 1 . Incr ease wat er line siz e. 2. W ater lt er clogged or [...]

43 V . R emov al and 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 vicing . 3. CHOKING[...]

44 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[...]

45 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 w ater -cooled model, see the nameplate f or the requir ed refrigerant charge . For[...]

46 1 0) R emov e the dr ier , then place the ne w drier in position. 1 1) Remov e the plugs from the suction, dischar ge , and process pipes . 1 2) Braze all  t tings while purging with nitr ogen g as  owing at a pressur e of 3 to 4 PSIG. 1 3) Use an electronic leak det ect or or soap b ubb les to chec k f or leaks. Add a tr ace of refrigeran[...]

47 9) Ev acuat e the s y st em, and charge it with r efr igerant. F or w ater -cooled model, see the nameplate f or the requir ed refrigerant charge . F or remot e air -cooled model, see the rating label inside the icemak er . 1 0) At tach the e xpansion v alv e b ulb t o the suction line in the same location as the pr e vious bulb . The bulb shoul[...]

48 1 2) Connect the ne w solenoid leads. 1 3) At tach the solenoid t o the val v e body and secur e it with the bolt. 1 4) Replace the panels in their corr ect positions . 1 5) T ur n on the pow er suppl y . E. Remo val and R eplacement of Evapor at or C A UTION 1 . Alw ay s install a ne w dr ier e ver y time the sealed r efrigeration s y st em is [...]

49 F . R emo val and R eplacement of W ater -Cooled Condenser C A UTION 1 . Alw ay s install a ne w dr ier e ver y time the sealed r efrigeration s y st em is opened. 2. Do not replace the drier until af t er all other r epair or r eplacement has been made. Install the ne w drier with the arro w on the drier in the direction of the refrigerant  [...]

50 G. Remo val and R eplacement of Remot e Air-Cooled Condenser C A UTION 1 . Alw ay s install a ne w dr ier e ver y time the sealed r efrigeration s y st em is opened. 2. Do not replace the drier until af t er all other r epair or r eplacement has been made. Install the ne w drier with the arro w on the drier in the direction of the refrigerant ?[...]

51 H. Remo val and R eplacement of W ater R egulating V alve (w ater -cooled model) C A UTION 1 . Alw ay s install a ne w dr ier e ver y time the sealed r efrigeration s y st em is opened. 2. Do not replace the drier until af t er all other r epair or r eplacement has been made. Install the ne w drier with the arro w on the drier in the direction o[...]

52 1 8) Check f or water leaks . 1 9) Replace the panels in their corr ect positions . 20) T ur n on the power suppl y . I. A djustment of W ater R egulating V alve - W ater -Cooled Model The wat er regulating v al v e (also called "w at er r egulat or") is f act or y -adjusted. No adjustment is requir ed under nor mal use. Adjust the w a[...]

53 8) Braz e all  t tings with nitrogen gas  owing at a pr essure of 3 to 4 PSIG. 9) Use an electronic leak det ector or soap b ubb les to chec k f or leaks. A dd a trace of refrigerant t o the sy st em (if using an electronic leak det ector), and then raise the pressur e using nitrogen g as (1 40 PSIG). DO NO T use R-404A as a mixture with p[...]

54 1 0) Secur e the insulation using the plastic cab le ties. 1 1) Connect the white thermistor connect or thr ough the b ushing of the contr ol bo x to the control boar d WHI TE K3 connect or . C A UTION! Do not shor ten or cut the ther mist or leads. 1 2) Replace the contr ol bo x cov er and the panels in their corr ect positions. 1 3) T ur n on [...]

55 9) Close the icemaker w ater suppl y line drain v alv e . Open the icemaker wat er supply line shut-of f val ve. 1 0) T ur n on the power suppl y . 1 1) Check f or leaks . 1 2) Replace the fr ont panel in its corr ect position. N. Remo val and R eplacement of Pump Mot or 1) T ur n of f the po wer suppl y . 2) Remo ve the fr ont panel. 3) Drain t[...]

56 O . Remo val and R eplacement of Contr ol Board 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 ailure due to st atic dischar ge . It is especially impor tant t o t ouch the metal par t of the unit bef or e handling or r eplacing the contr [...]

57 VI. Cleaning and Maintenance IMPOR T ANT Ensure all components , fast eners, and thumbscr ews ar e secur el y in place af ter any cleaning or maint enance is done to the equipment. A. Cleaning and Sanitizing Instructions W ARNING 1 . Hoshizaki recommends cleaning this icemak er at least once a year . More frequent cleaning , howe ver , may be r [...]

58 1 . Cleaning P r ocedur e 1) Dilute 38  . oz. (1,1 24 ml) of r ecommended cleaner Hoshizaki "Scale A wa y" with 7 gal. (26 l) of warm wat er . 2) Remo ve all ice fr om the e vaporat or and the storage bin. Note: T o r emov e cubes on the ev aporat or , tur n of f the power suppl y and tur n it back on af ter 3 minut es. The har vest[...]

59 1 8) Replace the fr ont panel in its corr ect position. 1 9) T ur n on the pow er suppl y t o  ll the wat er tank with wat er . 20) T ur n of f the po wer suppl y aft er 3 minutes . 21) Remo ve the fr ont panel and full y open the cleaning v al v e. 22) Mov e the control s witch to the "W ASH" position. 23) Replace the fr ont panel [...]

60 B. Maintenance IMPOR T ANT This icemaker m ust be maintained individuall y , ref erring to the instruction manual and labels pr o vided with the icemak er . 1 . Stainless St eel Exter ior T o pre vent corr osion, wipe the e xterior occasionally with a clean, sof t cloth. Use a damp cloth containing a neutral cleaner t o wipe of f oil or dir t bu[...]

61 2. Drain the w at er tank: 1) T ur n of f the po wer suppl y , then r emov e the front panel. Mov e the control s witch t o the "OFF" position. 2) Remo ve the insulation panel. Remo v e the cap locat ed on the fr ont bot tom par t of the ice dropping hole . Drain the wat er tank. See F ig . 7 . 3) Replace the cap and the insulation pan[...]