Hoshizaki KM-650MAH manual

1 Hoshizaki “A Superior Degree of Reliability” www .hoshizaki.com Models KM-650MAH KM-650MWH KM-650MRH Modular Crescent Cuber Hoshizaki America, Inc. S E RV I C E M A N U A L ™ Number: 73147 Issued: 12-12-2006[...]

2 IMPOR T ANT Only qualified ser vice technicians should attempt to ser vice or maintain this unit. No such ser vice or maintenance should be under taken until the technician has thoroughly read this Ser vice Manual. HOSHIZAKI provides this man ual primar ily to assist qualified ser vice technicians in the ser vice and maintenance of the unit. Sh[...]

3 Please re vie w this manual. It should be read carefully bef ore the icemaker is serviced or maintenance operations are perf or med. Only qualified ser vice technicians should ser vice and maintain the icemaker . This manual should be made a v ailab le to the technician prior to ser vice or maintenance. CONTENTS I. Specifications ..............[...]

4 III. T echnical Inf or mation ...................................................................................................... 23 A. W ater Circuit and Refr igeration Circuit ........................................................................ 23 1. KM-650MAH (air-cooled) .................................................................[...]

5 I. Specifications A. Icemaker 1. KM-650MAH (air-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. SPECIFICATION NO. 06A019 ISSUED: 10/10/2006 ITEM : HOSHIZAKI MODULAR CRESCENT CUBER MODEL: KM-650MAH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 6.6 A ( 5 Min. Freeze AT[...]

6 2. KM-650MWH (water-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. SPECIFICATION NO. 06A020 ISSUED: 10/10/2006 ITEM : HOSHIZAKI MODULAR CRESCENT CUBER MODEL: KM-650MWH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 5.3 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM C[...]

7 3. KM-650MRH (remote air-cooled) Note: We reserve the right to make changes in specifications and design without prior notice. SPECIFICATION DATA NO. 06A021 ITEM: HOSHIZAKI MODULAR CRESCENT CUBER MODEL: KM-650MRH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 7.1 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMP[...]

8 B. Condensing Unit 1. URC-5F 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 (SLO TTED HOLES) 17-1/8"[...]

9 Specifications MODEL: URC-5F SPECIFICATION NO. 06A022 ISSUED: 10/12/2006 ITEM: HOSHIZAKI REMOTE CONDENSER UNIT MODEL URC-5F BEGINNING SERIAL NO. ________________ ENDING SERIAL NO. ___________________ AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR 115 V Total 1.3FLA 65W EXTERIOR DIMENSIONS (WxDxH) 21-15/16" x 15-11/16" x [...]

10 II. General Information A. Construction 1. KM-650MAH (air-cooled) Bin Control Ther mostat W ater Supply Inlet Condenser Drier Control Bo x Spra y T ubes Control Switch W ater Pump Float Switch Compressor Expansion V alve F an Motor Hot Gas V alve[...]

11 2. KM-650MWH (water-cooled) Bin Control Ther mostat W ater Supply Inlet Condenser Drier Control Bo x Spra y T ubes Control Switch W ater Pump Float Switch Compressor Expansion V alve W ater Regulator V alv e Hot Gas V alve[...]

12 3. KM-650MRH (remote air-cooled) Bin Control Ther mostat Receiv er T ank W ater Supply Inlet Junction Bo x Drier Control Bo x Spra y T ubes Control Switch W ater Pump Float Switch Compressor Expansion V alve Hot Gas V alve Liquid Line V alve[...]

13 B. Sequence of Operation The steps in the sequence are as outlined below . When po wer is supplied, a 5 second dela y occurs at star tup . Note that the order of the LEDs from the outer edge of the board is 1, 4, 3, 2. 1. One Minute Fill Cycle LED 4 is on. WV opens and the fill period begins. After 1 minute, the board chec ks f or a closed F/S.[...]

14 Components Energized when the Contr ol Switch is in the W ASH P osition The W ASH position on the control switch is used when cleaning and sanitizing the unit. When in the W ASH position, power is supplied to the pump motor . With the cleaning v alve closed, the cleaner and sanitiz er flow ov er the outside of the e v aporator plate assemb ly .[...]

15 C. Control Boar d • A HOSHIZAKI e xclusiv e solid-state control is emplo yed in KM-650MAH, KM-650MWH and KM-650MRH Modular Crescent Cubers. • All models are pretested and f actor y-adjusted. CA UTION 1. F ragile , handle v er y carefully . 2. A control board contains integrated circuits, which are susceptib le to failure due to static discha[...]

16 Control Boar d P ar t Number 2A1410-01 (f actor y); 2A1410-02 (service) T ype HOS-001A (Control Products - 10 Pin) Contr ol Pr oducts "E" Contr ol Boar d 1. Control Boar d La y out Output T est Switch (used to test rela ys on board) Connector K3 Har v est Control (thermistor) Connector K4 Open (not connected) Microprocessor (board re v[...]

17 2. Features a) Maximum W ater Supply P eriod – 6 minutes Inlet water v alve opening, in the harvest cycle , is limited by the harvest timer . The water v alv e cannot remain open longer than the maximum period. The w ater v alv e can close in less than six minutes if the harvest cycle is completed. b) Harvest Backup Timer and Freeze Timer The [...]

18 f) LED Lights and A udible Alarm Saf eties The red LED indicates proper control v oltage and will remain on unless a control v oltage problem occurs . At star tup a 5 second delay occurs while the board conducts an internal timer check. A shor t beep occurs when the power s witch is tur ned OFF . The green LEDs 1 through 4 energiz e and sequence[...]

19 3. Controls and Adjustments a) Default Dip Switch Settings The dip s witch is f actor y-adjusted to the follo wing positions: Dip Switch No . 1 2 3 4 5 6 7 8 9 10 KM-650MAH OFF OFF OFF OFF ON ON OFF OFF OFF OFF KM-650MWH OFF OFF OFF OFF ON ON OFF OFF OFF OFF KM-650MRH OFF OFF OFF OFF ON ON OFF OFF ON OFF F reeze Timer (9 & 10) Pump-Out F req[...]

20 c) Harvest Timer (dip switch 1 & 2) The har v est timer star ts counting when the ther mistor reads 48°F (9°C) at the e v aporator outlet. No adjustment is required under nor mal use, as the harvest timer is adjusted to the suitable position. How e ver , a setting longer than the factory setting may be advised in cases where the flush pro[...]

21 e) Pump-Out Frequency Contr ol (dip s witch 5 & 6) The pump motor drains the w ater tank at the frequency set b y the pump-out frequency control. The pump-out frequency control is f actor y-adjusted to drain the w ater tank e very 10 cycles, and no adjustment is required. How e v er , where water quality is bad and the icemaker needs a pump [...]

22 4. Control Boar d Chec k Procedure Bef ore replacing a control board that does not sho w a visible def ect and that you suspect is bad, alwa ys conduct the f ollowing chec k procedure. This procedure will help y ou v erify your diagnosis . 1) Check the dip s witch settings to assure that #3, 4, 7, 8, 9, & 10 are in the f actor y def ault pos[...]

23 III. T echnical Inf ormation A. W ater Cir cuit and Refrigeration Circuit 1. KM-650MAH (air-cooled)[...]

24 2. KM-650MWH (water-cooled)[...]

25 3. KM-650MRH (remote air-cooled)[...]

26 B. Wiring Diagrams 1. KM-650MAH (air-cooled) and KM-650MWH (water -cooled) * Pressure Switch Air-Cooled Model W ater-Cooled Model Cut-out 412± 21 PSIG 384± 21 PSIG Cut-in 327±21 PSIG 284±21 PSIG 0 0 12V *[...]

27 * 2. KM-650MRH (remote air-cooled) * Pressure Switch Cut-out 412± 21 PSIG Cut-in 327±21 PSIG 0 12V[...]

28 C. P erf ormance Data 1. KM-650MAH (air-cooled) PERFORMANCE DATA NO. 06A019 ISSUED: 10/10/2006 ITEM : HOSHIZAKI MODULAR CRESCENT CUBER MODEL: KM-650MAH 70/21 589 267 566 257 526 238 80/27 572 259 537 243 490 222 90/32 566 257 512 232 467 212 lbs./day kg./day 100/38 555 252 501 227 426 193 70/21 80/27 90/32 watts 100/38 70/21 257 0.97 214 0.81 19[...]

29 PERFORMANCE DATA NO. 06A020 ISSUED: 10/10/2006 ITEM : HOSHIZAKI MODULAR CRESCENT CUBER MODEL: KM-650MWH 70/21 680 308 675 306 626 284 80/27 676 307 668 303 595 270 90/32 675 306 662 300 598 271 lbs./day kg./day 100/38 651 295 647 294 540 245 70/21 80/27 90/32 watts 100/38 70/21 662 2.51 729 2.76 1173 4.44 80/27 713 2.70 817 3.09 1457 5.52 90/32 [...]

30 3. KM-650MRH (remote air-cooled) PERFORMANCE DATA NO. 06A021 ISSUED: 10/10/2006 ITEM : HOSHIZAKI MODULAR CRESCENT CUBER MODEL: KM-650MRH 70/21 615 279 597 271 556 252 80/27 601 273 574 260 523 237 90/32 597 271 554 251 506 230 lbs./day kg./day 100/38 583 264 543 246 462 210 70/21 80/27 90/32 watts 100/38 70/21 266 1.01 220 0.83 198 0.75 80/27 23[...]

31 IV . Service Diagnosis A. 10-Minute KM Diagnostic Pr ocedure The 10 minute chec k out procedure is basically a sequence chec k which can be used at unit star t-up or for system diagnosis . Using this check out procedure will allo w y ou to diagnose electrical system and component failures in appro ximately 10 minutes under nor mal operating cond[...]

32 freeze with the float s witch remov ed, replace the board. Note: Nor mal freeze cycle will last 20 to 40 min utes depending on model and conditions. Cycle times and pressures should f ollow perf or mance data provided in this manual. 6) Pump-Out Cycle (10/20 second pump out) – the compressor remains energiz ed, the hot gas v alv e energizes ,[...]

33 Prob lem P ossible Cause Remedy [1] The icemaker will not star t. (continued) e) High Pressure Control (continued) 3. Ambient or condenser water temper ature too warm. 3. Reduce temperature. 4. Refrigerant ov ercharged. 4. Recharge. 5. F an not operating. (e xcept water-cooled model) 5. See char t 1.[6] 6. Refrigerant line or components plugged.[...]

34 Prob lem P ossible Cause Remedy [1] The icemaker will not star t. (continued) m) Interlock Switch (Cleaning V alve) 1. OFF position. 1. Mov e to ON position. 2. Bad contacts. 2. Check f or continuity and replace. n) W ash Switch 1. W ASH position. 1. Mov e to ICE position. 2. Bad contacts. 2. Check and replace . [2] W ater continues to be suppli[...]

35 Prob lem P ossible Cause Remedy [5] No water comes from spra y tubes. W ater pump will not star t, or freeze cycle time is too shor t. (continued) c) W ater System (continued) 2. Clogged. 2. Clean. 3. Pump out check v alv e leaking by . 3. Check assemb ly and clean. d) Pump Motor 1. Motor winding opened. 1. Replace. 2. Bearing wor n out. 2. Repl[...]

36 2. Evaporator is Fr ozen Up Prob lem P ossible Cause Remedy [1] F reeze cycle time is too long. a) Float Switch 1. Leads shor t-circuit or def ectiv e s witch. 1. Check and replace . 2. Float does not mov e freely . 2. Clean or replace. b) Inlet Water V alve 1. Diaphragm does not close. 1. Check f or water leaks with icemaker off . c) Control Bo[...]

37 Prob lem P ossible Cause Remedy [3] Other (continued) g) Water Supply Line 1. T oo small; requires 3/8" OD line dedicated per machine. 1. Increase water line size . h) W ater Filter 1. Flow rate too small. 1. Replace with filter that has larger flow r ate. 3. Low Ice Pr oduction Prob lem P ossible Cause Remedy [1] F reeze cycle time is lo[...]

38 Prob lem P ossible Cause Remedy [2] Abnormal noise. (continued) c) Compressor (continued) 2. Mounting pad out of position. 2. Reinstall. d) Refrigerant Lines 1. Rub or touch other lines or surf aces. 1. Replace. [3] Ice in storage bin often melts. a) Drain Line(s) 1. Plugged. 1. Clean. b) Icemaker and Bin 1. Dr ains not run separately . 1. Separ[...]

39 V . Remo v al and Replacement of Components IMPOR T ANT Ensure all components, f asteners and thumbscrews are securely in place after the equipment is ser viced. IMPOR T ANT 1. The P oly ol Ester (POE) oils used in R-404A units can absorb moisture quickly . Theref ore it is impor tant to prev ent moisture from enter ing the system when replacing[...]

40 6) A liquid charge is recommended f or charging an R-404A system. Inv er t the service cylinder and place it on scales. Open the high-side, service manifold v alve . 7) Allow the system to charge with liquid until the proper charge w eight is met. 8) If necessar y , add any remaining charge to the system through the lo w-side. Use a throttling v[...]

41 2) Remov e the panels. 3) Recov er the refr igerant and store it in an appro v ed container . 4) Remov e the ter minal cov er on the compressor and disconnect the compressor wir ing. 5) Remov e the hold-down bolts, w ashers and r ubber grommets . 6) Remov e the discharge and suction pipes. 7) Remov e the compressor . Unpack the ne w compressor p[...]

42 E. Remov al and Replacement of Expansion V alve IMPOR T ANT Sometimes moisture in the refrigeration circuit e xceeds the drier capacity and freezes up at the e xpansion valv e. Alwa ys install a new drier ev er y time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made. 1)[...]

43 F . Remo v al and Replacement of Hot Gas V alve and Line V alve IMPOR T ANT 1. Alwa ys use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the perf or mance ma y be reduced. 2. Alwa ys install a new drier ev er y time the sealed refr igeration system is opened. Do not replace the dr ier until after all o[...]

44 G. Remov al and Replacement of Evaporator IMPOR T ANT Alwa ys install a new drier e v er y time the sealed refrigeration system is opened. Do not replace the drier until after all other repairs or replacement hav e been made. 1) T ur n off the power supply . 2) Remov e the panels and the top insulation ov er the e vaporator . 3) Recov er the ref[...]

45 7) Remov e the screws and the v alve from the brac ket. 8) Install the new v alve . 9) Remov e the dr ier , then place the new drier in position. 10) Braz e all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG. 11) Check f or leaks using nitrogen gas (140 PSIG) and soap bub b les. 12) Ev acuate the system, and char[...]

46 J . Remov al and Replacement of Headmaster (Condensing Pressure Regulator - C.P .R.) - Remote Air-Cooled Model Onl y IMPOR T ANT Alwa ys install a new drier e v er y time the sealed refrigeration system is opened. Do not replace the drier until after all other repair or replacement has been made. 1) T ur n off the power supply . 2) Remov e the p[...]

47 K. Remov al and Replacement of Thermistor IMPOR T ANT 1. F ragile , handle v er y carefully . 2. Alwa ys use a recommended sealant (High Ther mal Conductiv e T ype), Model KE4560R TV manuf actured by SHINETSU SILICONE, P ar t Code 60Y000- 11, or P ar t Code 4A0683-01 equiv alent. 3. Alwa ys use a recommended f oam insulation (Non-absorbent T ype[...]

48 3) Remov e the junction box co ver from the remote condenser unit (remote air-cooled model). 4) Remov e the closed end connectors from the fan motor leads . 5) Remov e the fan motor br ac ket and f an motor . 6) Install the new f an motor and replace the remov ed par ts in the re verse order of which they w ere remo v ed. 7) Replace the panels i[...]

49 9) Remov e the screw attaching the pump motor to the pump motor brac ket. 10) Remov e the screws attaching the pump housing to the pump motor . Remov e the housing and check the impeller . 11) If the impeller is def ectiv e , install a new impeller . 12) Install the new motor or ne w par ts , and replace the remo v ed par ts in the re v erse ord[...]

50 VI. Cleaning and Maintenance Instructions IMPOR T ANT Ensure all components, f asteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. A. Cleaning and Sanitizing Procedures W ARNING 1. HOSHIZAKI recommends cleaning this unit at least once a year . More frequent cleaning, how e v er , ma y be req[...]

51 1. Cleaning Procedure 1) Dilute appro ximately 16 fl. oz. of the recommended cleaner Hoshizaki "Scale A wa y" or "LIME-A-W A Y" (Economics Laborator y , Inc.) with 3 gal. (11 l) of water . 2) Remov e all ice from the ev aporator and the storage bin. Note: T o remov e cubes on the e v aporator , tur n off the power supply and[...]

52 20) Remov e the front panel and fully open the cleaning valv e. 21) Mov e the control switch to the "W ASH" position. 22) Replace the front panel in its correct position. 23) T ur n on the power supply to rinse off the cleaning solution. 24) T ur n off the power supply after 5 min utes. 25) Remov e the front panel. 26) Remov e one end [...]

53 damp cloth containing a neutral cleaner to wipe off oil or dir t build up . 2. Storage Bin and Scoop • W ash y our hands bef ore remo ving ice. Use the plastic scoop provided (bin accessory). • The storage bin is f or ice use only . Do not store anything else in the bin. • K eep the scoop clean. Clean it by using a neutr al cleaner and rin[...]

54 10) Blow the w ater-cooled condenser out, using compressed air or carbon dio xide until water stops coming out. 2. Drain the potable water supply line: 1) Remov e the front panel. 2) Mov e the control switch on the control bo x to the "OFF" position. 3) W ait 3 minutes . 4) Close the potable w ater supply line shut-off valv e and open [...]