Hoshizaki KM-150BAF Service Manual
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Hoshizaki KM-150BAF Service Manual

Hoshizaki KM-150BAF Service Manual

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Reliability is a
beautiful thing
TM
SERVICE MANUAL
CRESCENT CUBER
KM-150BAF
KM-150BWF
NUMBER:
ISSUED:
FEB. 27, 1998
™
REVISED: DEC. 14, 2003
73066

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Summary of Contents for Hoshizaki KM-150BAF

  • Page 1 Reliability is a beautiful thing CRESCENT CUBER KM-150BAF KM-150BWF SERVICE MANUAL NUMBER: 73066 ISSUED: FEB. 27, 1998 ™ REVISED: DEC. 14, 2003...
  • Page 2 No such service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. HOSHIZAKI provides this manual primarily to assist qualified service technicians in the service and maintenance of the icemaker. Should the reader have any questions or concerns which have not been satisfactorily addressed, please call or write to the HOSHIZAKI Technical Support Department for assistance.

  • Page 3: Table Of Contents

    This manual should be made available to the technician prior to service or maintenance. CONTENTS PAGE I. SPECIFICATIONS ....................5 1. KM-150BAF (Air-cooled) ..................5 2. KM-150BWF (Water-cooled) ................6 II. GENERAL INFORMATION ..................7 1. CONSTRUCTION ....................7 [a] KM-150BAF ....................7 [b] KM-150BWF ....................
  • Page 4 V. REMOVAL AND REPLACEMENT OF COMPONENTS.......... 37 1. SERVICE FOR REFRIGERANT LINES .............. 37 [a] REFRIGERANT RECOVERY ................ 37 [b] EVACUATION AND RECHARGE ..............37 2. BRAZING ......................38 3. REMOVAL AND REPLACEMENT OF COMPRESSOR........39 4. REMOVAL AND REPLACEMENT OF DRIER ............ 40 5.

  • Page 5: Specifications

    I. SPECIFICATIONS 1. KM-150BAF...

  • Page 6: Km-150Bwf (Water-Cooled)

    2. KM-150BWF...

  • Page 7: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION [a] KM-150BAF...
  • Page 8 [b] KM-150BWF...

  • Page 9: [B] Km-150Bwf

    2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KM-150BAF and KM-150BWF 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.
  • Page 10 MY9KM910 (Alpine) MY9KM91B (Alpine) OR the Control Products Board (green): PART NUMBER TYPE 2A0836-01 HOSHIZAKI 001 (Control Products - 8 Pin) OR the Control Products Improved “E” Board (green): PART NUMBER TYPE 2A1410-01 HOS-001A (Control Products - 10 Pin) Features of All Three Controller Boards...
  • Page 11 This High Temperature Safety shuts down the circuit and the icemaker automatically stops. To reset the safety, turn the power off and back on again. This High Temperature Safety protects the unit from excessive temperature. (4) Low Water Safety If the Pump Motor is operated without water, the mechanical seal can fail. To prevent this type of failure, the Controller Board checks the position of the Float Switch at the end of the initial one minute water fill cycle and at the end of each defrost cycle.
  • Page 12 Connector K1 Pins #1 through #10 #1, 9 Magnetic Contactor Hot Gas Valve Line Valve Pump Motor (icemaking) Pump Motor (drain) Water Valve #7, 10 Power (line, Bin Control) Open Dip Switch Defrost Timer, Drain Timer & Drain Counter Connector K5 Float Switch Connector K4 Open...
  • Page 13 Features of Control Products “E” Controller Board The “E” board includes LED lights and audible alarm safeties. The red LED indicates proper control voltage and will remain on unless a control voltage problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check.
  • Page 14 (Control Products HOSHIZAKI001 Board)
  • Page 15 (Control Products HOS-001A Board)

  • Page 16: [C] Sequence

    [c] SEQUENCE 1st Cycle 3. Thermistor reads 48° F (9°C). 1. Unit energized and Control Switch to “ICE” Defrost Timer, adjustable from position. Water supply cycle starts. 1 to 3 minutes, starts counting. 2. After 1 minute, Defrost cycle starts. IMPORTANT Water Valve opening is limited...
  • Page 17 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 2. Thermistor reads 48° F (9°C). freeze cycle. 10/20 second Drain Timer starts Defrost Timer, adjustable from counting.

  • Page 18: [D] Controls And Adjustments

    [d] CONTROLS AND ADJUSTMENTS The Dip Switch is factory-adjusted to the following positions: DIP SWITCH NO. 2U0127-01 (BAF, BWF) OFF 2A0836-01 (BAF, BWF) OFF 2A1410-01 (BAF) 2A1410-01 (BWF) 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.
  • Page 19 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 check the Thermistor mounting, located on the Suction Line next to the Evaporator outlet.
  • Page 20 3) Drain Timer The Drain Timer is factory-adjusted, and no adjustment is required. SETTING TIME Dip Switch Dip Switch No. 3 No. 4 10 seconds 150 seconds 10 seconds 180 seconds 10 seconds 120 seconds 20 seconds 180 seconds T1: Time to drain the Water Tank T2: Time to restrain defrost completion 4) Freeze Timer CAUTION...

  • Page 21: [E] Checking The Controller Board

    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.
  • Page 22 [ALPINE BOARD ONLY] 3) Check the Controller Board by using test program of the Alpine Controller Board (next page). (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 current flows to each Relay (from X1 to X4) one after another every time the float is raised and the contacts close.
  • Page 23 • TEST PROGRAM OF ALPINE CONTROLLER BOARD...

  • Page 24: Switches

    3. SWITCHES Control Switch The Control Switch is located on the lower left section of the Control Box (B) when facing the front of the machine. This switch is used to place the machine into one of three modes: “OFF” (center position), “ICE”...

  • Page 25: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] KM-150BAF...
  • Page 26 [b] KM-150BWF...

  • Page 27: [A] Km-150Baf (Air-Cooled)

    2. WIRING DIAGRAM KM-150BAF, KM-150BWF Note: Pressure Switch - HI KM-150BWF KM-150BAF +21.3 +21.3 Cut-out 412.5 PSIG Cut-out 376.9 PSIG Cut-in 327.1 ±21.3 PSIG Cut-in 270.2 ±21.3 PSIG...

  • Page 28: Timing Chart

    3. TIMING CHART The Pump Motor for KM-150B series does not have drain cycle. The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”...
  • Page 29 The Pump Motor for KM-150B series does not have drain cycle. The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”...

  • Page 30: Performance Data

    4. PERFORMANCE DATA [a] KM-150BAF (Air-cooled)

  • Page 31: [B] Km-150Bwf (Water-Cooled)

    [b] KM-150BWF (Water-cooled)

  • Page 32: Service Diagnosis

    IV. SERVICE DIAGNOSIS 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.
  • Page 33 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.
  • Page 34 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.

  • Page 35: Evaporator Is Frozen Up

    2. EVAPORATOR IS FROZEN UP 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.

  • Page 36: Low Ice Production

    3. LOW ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] Freeze cycle a) See chart 1 - [3], and check dirty Air Filter or Condenser, ambient or water time is long. temperature, water pressure or refrigerant charge. b) See chart 2 - [1], and check Float Switch, Water Solenoid Valve or Controller Board.

  • Page 37: Removal And Replacement Of Components

    REMOVAL AND REPLACEMENT OF COMPONENTS IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORTANT 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 servicing parts.

  • Page 38: Brazing

    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 recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No.

  • Page 39: Removal And Replacement Of Compressor

    3. REMOVAL AND REPLACEMENT OF COMPRESSOR 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. Note: When replacing a Compressor with a defective winding, be sure to install the new Start Capacitor and Start Relay supplied with the replacement Compressor.

  • Page 40: Removal And Replacement Of Drier

    15) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required refrigerant charge. 16) Connect the Terminals, and replace the Terminal Cover in its correct position. 17) Slide in the refrigeration base and replace the Front Panel in its correct position. 18) Plug in the icemaker, and turn on the power supply.

  • Page 41: Removal And Replacement Of Expansion Valve

    5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE 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.

  • Page 42: Removal And Replacement Of Hot Gas Valve

    6. REMOVAL AND REPLACEMENT OF HOT GAS VALVE CAUTION Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced. IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened.

  • Page 43: Removal And Replacement Of Evaporator

    7. REMOVAL AND REPLACEMENT OF EVAPORATOR IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened. Do not replace the Drier until after all other repairs or replacements have been made. 1) Turn off the power supply, and unplug the icemaker. 2) Remove the panels and the Top Insulation over the Evaporator.

  • Page 44: Removal And Replacement Of Water-Regulating Valve

    8. REMOVAL AND REPLACEMENT OF WATER REGULATING VALVE - WATER-COOLED MODEL ONLY 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, and unplug the icemaker.

  • Page 45: Adjustment Of Water-Regulating Valve

    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, using the following procedures. 1) Attach a pressure gauge to the high-side line of the system or prepare a thermometer to check for the condenser drain temperature.

  • Page 46: Removal And Replacement Of Thermistor

    10. REMOVAL 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.

  • Page 47: Removal And Replacement Of Fan Motor

    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) Plug in the icemaker, and turn on the power supply.

  • Page 48: Removal And Replacement Of Pump Motor

    7) Remove the Fitting and the Gasket. 8) Release the Hose Clamp, and disconnect the Hose. 9) Remove the Water Valve from the Rear Panel. 10) Install the new Water Valve, and replace the removed parts in the reverse order of which they were removed.

  • Page 49: Removal And Replacement Of Float Switch

    12) Close the Bin Door. 13) Replace the panels in their correct positions. 14) Plug in the icemaker, and turn on the power supply. 14. REMOVAL AND REPLACEMENT OF FLOAT SWITCH 1) Go through the steps 1) through 7) in “13. REMOVAL AND REPLACEMENT OF PUMP MOTOR.”...

  • Page 50: Cleaning And Maintenance Instructions

    VI. CLEANING AND MAINTENANCE INSTRUCTIONS 1. PREPARING THE ICEMAKER FOR LONG STORAGE IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. WARNING When shutting off the icemaker for an extended time, drain out all water from the water tank and remove the ice from the Storage Bin.
  • Page 51 [2] Remove the water from the potable water supply line: 1) Remove the Front Panel. (Except 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.

  • Page 52: Cleaning And Sanitizing Procedures

    This will prevent irritation in case the solutions come into contact with skin. [a] CLEANING PROCEDURE 1) Dilute approximately 5 fl. oz. (148 ml.) of recommended cleaner, Hoshizaki “Scale Away” or “Lime-A-Way” (Economics Laboratory, Inc.) with 1 gal. (3.8 l.) of warm water. 2) Remove the Front Panel.
  • Page 53 18) Remove the Water Tank Brackets and the Thermostat Bracket from the Bin by removing the Thumbscrews. 19) Dilute approximately 5 fl. oz. (148 ml.) of recommended cleaner Hoshizaki “Scale Away” or “Lime-A-Way” (Economics Laboratory, Inc.) with 1 gal. (3.8 l.) of water.

  • Page 54: [B] Sanitizing Procedure

    [b] SANITIZING PROCEDURE - Following Cleaning Procedure 1) Dilute a 5.25% Sodium Hypochlorite solution (chlorine bleach) with water. [Add 0.5 fl. oz. (15 ml.) of sanitizer to 1 gal. (3.8 l.) of water.] 2) Wash the bin liner, the Thermostat Bracket, the Water Tank Brackets and the Water Tank using the above sanitizing solution.

  • Page 55: Maintenance

    3. MAINTENANCE IMPORTANT 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) Storage Bin and Scoop •...

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Km-150bwf

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