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Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber with "G" Control Board Models KMD-460MAH, MWH KMD-530MAH, MWH, MRH KML-250MAH, MWH KML-351MAH, MWH KML-451MAH, MWH KML-631MAH, MWH, MRH SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com Number: 73205 Issued: 5-7-2015...
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Should the reader have any questions or concerns which have not been satisfactorily addressed, please call, send an e-mail message, or write to the Hoshizaki Technical Support Department for assistance.
IMPORTANT This manual should be read carefully before the appliance is serviced. Read the warnings and guidelines contained in this manual carefully as they provide essential information for the continued safe use, service, and maintenance of the appliance. Retain this manual for any further reference that may be necessary. CONTENTS Important Safety Information ....................
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VI. Preparing the Appliance for Periods of Non-Use ............54 VII. Disposal ......................... 56 VIII. Technical Information ....................57 A. Specification and Performance Data Sheets ............... 57 1. KMD-460MAH ......................57 2. KMD-460MWH ...................... 58 3. KMD-530MAH ....................... 59 4. KMD-530MWH ...................... 60 5.
Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury.
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WARNING, continued • Children should be properly supervised around this appliance. • Do not climb, stand, or hang on the appliance or allow children or animals to do so. Serious injury could occur or the appliance could be damaged. • Do not use combustible spray or place volatile or flammable substances near the appliance.
Bin Control Condenser Pump Motor Fan Motor Control Switch High-Pressure Service Switch Switch Float Switch Compressor Thermostatic Bin Control Drier Liquid Line Valve Bracket & Bulb Holder Control Box Model Shown: KML-351MAH Mechanical Bin Control and Bracket Model Shown: KMD-460MAH...
2. Water-Cooled (MWH) Thermostatic Water Supply Inlet Spray Tubes Expansion Valve Water Regulating Drain Valve Valve Cleaning Valve Inlet Water Valve Condenser Thermostatic Bin Control High-Pressure Switch Control Box Pump Motor Float Switch Drier Compressor Hot Gas Valve Control Switch Thermostatic Bin Control Service Switch Bracket &...
3. Remote Air-Cooled (MRH) Thermostatic Spray Tubes Expansion Valve Water Supply Inlet Drain Valve Cleaning Valve Hot Gas Valve Inlet Water Valve Cleaning Valve Control Box Control Switch High-Pressure Switch Service Switch Pump Motor Reciever Drier Float Switch Thermostatic Liquid Line Valve Bin Control Compressor Crankcase Heater...
B. Service Diagnosis WARNING • The appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Risk of electric shock. Control switch in "OFF" position does not de-energize all loads Use extreme caution and exercise safe electrical practices.
1. "G" Control Board without Harvest Pump Timer Operation Diagnosis 3) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5-sec. delay occurs. CB red "POWER OK" LED and green "BC CLOSED" LED turn on.
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4) 1-Minute Fill Cycle – LED 4 is on. WV energizes. After 1 min., CB checks for a closed FS. If FS is closed, harvest cycle begins. If harvest cycle begins (Comp, HGV, and FMR energize), continue to step 5. If FS is open, WV remains energized through additional 1-min.
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e) Initial Harvest Cycle Termination Diagnosis: When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2). Check discharge line temperature. For a thermistor check, see "II.F. Thermistor Check." If 1-min. fill cycle starts after harvest timer terminates, check that FS is clean and operating properly, see "II.E.
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d) PM Diagnosis: Confirm water is flowing over evaporator from PM and not WV. If PM de-energizes once freeze begins, check for 115VAC at CB K1 #4 (R) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present and PM is de-energized, check for 115VAC at control switch #5 (Y) to neutral (W).
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7) Pump-Out Cycle – LEDs 1, 3, and 2 are on (10/20 second pump-out). Timing of the first pump-out is dependent on CB. The first pump-out is determined by S4 dip switch 5 & 6. See the table below. "G" Control Board Settings 1st Pump-Out S4 Dip Switch Setting Pump-Out...
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9) Shutdown a) Thermostatic Bin Control (TBC): When the appliance is running, hold ice in contact with the thermostatic bulb. BC switch opens within 10 sec., shutting down the appliance. TBC is factory set, and generally no adjustment is required. However, adjustment may be needed in some conditions, particularly at higher altitude locations.
2. "G" Control Board with Harvest Pump Timer Operation Diagnosis 3) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5-sec. delay occurs. CB red "POWER OK" LED and green "BC CLOSED" LED turn on.
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4) 1-Min. Fill Cycle – LED 4 is on. WV and X11 relay energize. After 1 min., CB checks for a closed FS. If FS is closed, the harvest cycle begins (X10, Comp, HGV, FMR energize), Continue to step 5a. If FS is open, WV remains energized through additional 1-min.
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5b) Harvest Pump Timer – LEDs 1, 3, and 2 are on. When the thermistor reaches 48°F (9°C), CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2). 50 sec. before the harvest timer terminates, LED turns on and PM energizes.
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b) Comp and FMR Diagnosis: If Comp and FMR de-energize once freeze begins, check that appliance has not shut off on HPS ("POWER OK" LED off). If so, check "3)b) HPS Diagnosis." If "POWER OK" LED is on, check for 115VAC at CB K1 #1 (V) or #9 (V) to neutral (W).
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h) Freeze Termination Diagnosis: After 5 min. in freeze, disconnect CB K5 FS connector. 15 sec. later appliance should switch out of the freeze cycle (15 second delay after FS opens before terminating the freeze cycle). If appliance remains in freeze longer than 15 sec.
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Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after 5 min. of freeze disconnect CB black K5 connector (FS connector). Check that PM stops and re-starts and that DV energizes and water is flowing down the drain through DV.
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9) Shutdown a) Thermostatic Bin Control (TBC): When the appliance is running, hold ice in contact with the thermostatic bulb. BC switch opens within 10 sec., shutting down the appliance. TBC is factory set, and generally no adjustment is required. However, adjustment may be needed in some conditions, particularly at higher altitude locations.
C. Control Board Check Before replacing CB that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis. Alarm Reset: If CB is in alarm (beeping), press the "ALARM RESET" button on CB while CB is beeping.
D. Bin Control Check 1. Thermostatic Bin Control Check TBC shuts down the icemaker within 10 sec. when ice contacts the thermostatic bulb, regardless of the cycle at activation. NOTICE When the ambient temperature is below 45°F (7°C), TBC opens and shuts down the appliance even if the ice storage bin is empty.
2. Mechanical Bin Control Check and Cleaning a) Mechanical Bin Control Check A lever-actuated proximity switch is used to control the ice level in the storage bin. No adjustment is required. To check MBC, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF"...
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5) Remove the actuator paddle from the switch mount. See Fig. 2. 6) Wipe down MBC with a mixture of 1 part of Hoshizaki "Scale Away" and 25 parts of warm water. Rinse the parts thoroughly with clean water.
E. Float Switch Check and Cleaning FS is used to determine that there is sufficient water in the water tank after the 1-min. fill cycle and after each harvest cycle. FS is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle. No adjustment is required.
Be careful not to bend the retainer rod excessively when removing it. See Fig. 3. 6) Wipe down FS housing, shaft, float, and retainer rod with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Rinse the parts thoroughly with clean water.
F. Thermistor Check To check thermistor resistance, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel. Move the control switch to the "OFF" position. 3) Remove the control box cover. 4) Remove the thermistor from the refrigerant tubing. 5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min.
G. Diagnostic Tables 1. No Ice Production No Ice Production - Possible Cause 1. Power Supply a) Off, blown fuse, or tripped breaker. b) Not within specifications. 2. Fuse (inside fused disconnect, a) Blown. if any) 3. Thermostatic Bin Control a) Tripped with bin filled with ice.
Water leaks causing short freeze time. 2. Freeze-Up Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up checklist. See the Hoshizaki America Technician's Pocket Guide or contact your local distributor for a copy of the freeze-up checklist. Freeze-Up - Possible Cause Harvest Cycle 1.
Freeze-Up - Possible Cause 10. Thermistor a) Loose, disconnected, or defective. See "II.F. Thermistor Check" 11. Thermostatic Expansion Valve a) Defective. 12. Hot Gas Valve a) Closed or restricted. 13. Liquid Line Valve a) Open. Freeze Cycle 1. Evaporator a) Scaled up. b) Damaged.
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Low Ice Production - Possible Cause 10. Liquid Line Valve a) Erratic or open. 11. Thermostatic Expansion Valve a) Defective. Long Freeze Cycle 1. Evaporator a) Scaled up, dirty. 2. Float Switch a) Scaled up, dirty. See "II.E. Float Switch Check b) Float sticking.
III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KMD and KML series appliances. • All models are pretested and factory adjusted. • For a control board check procedure, see "II.C. Control Board Check." NOTICE • Fragile, handle very carefully.
A. Control Board Layout "G" Control Board • Bin Control Switch Closed LED (green) • "OUTPUT TEST" Button • S4 Dip Switch • "ALARM RESET" Button (on continuously (used to test relays on control board) in thermostatic bin control application) •...
B. LED Lights and Audible Alarm Safeties At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when the control switch is moved to the "ICE" position. The red "POWER OK" LED indicates proper control voltage and remains on unless a control voltage problem occurs.
NOTICE Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. For more information, contact your Hoshizaki Service Center. 1. Default Dip Switch Settings The dip switches are factory-adjusted to the following positions: a) "G"...
Before changing this setting, contact Hoshizaki Technical Support at 1-800-233-1940 for recommendations. Keep in mind that setting the harvest timer to a longer setting decreases 24-hour production.
4. Pump-Out Frequency Control (S4 dip switch 5 & 6) The pump-out frequency control is factory set. Generally no adjustment is required. However, where water quality is bad and the icemaker needs a pump-out more often, the pump-out frequency can be adjusted. The pump-out frequency control can be set to have a pump-out occur every cycle, or every 2, 5, or 10 cycles.
In this case, see "II.G.3. Low Ice Production" for possible solutions. The freeze timer is factory set and no adjustment is required. Before changing this setting, contact Hoshizaki Technical Support at 1-800-233-1940 for recommendations.
D. Switches Two control switches are used to control operation in KMD and KML Series Modular Crescent Cubers. These switches are referred to as the "control switch" and the "service switch" and are located on the control box. 1. Control Switch The control switch has three positions: "OFF"...
IV. Refrigeration Circuit and Component Service Information WARNING • This appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Move the control switch to the "OFF" position and turn off the power supply. Place the disconnect in the "OFF"...
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2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). • R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R-404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous.
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Remember to loosen the connection and purge the air from the hose. For the required refrigerant charge, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets AHRI Standard 700 (latest edition) be used.
• The thermistor should be at the 12 o'clock position on the tube. • Smoothly fill the recessed area of the thermistor holder with high thermal conductive type sealant. Hoshizaki America part number 4A0683-01 (Silicone Heat Sink Compound 10-8108 manufactured by GC Electronics), KE-4560 RTV (manufactured by ShinEtsu Silicones), or equivalent are recommended.
V. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the appliance's environment, and local sanitation regulations WARNING • Only qualified service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the control switch or service switch with damp hands •...
VI. Preparing the Appliance for Periods of Non-Use NOTICE • When storing the appliance for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. • The pump motor is energized continuously when the control switch is in the "SERVICE"...
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3. On water-cooled model, remove the water from the water-cooled condenser: 1) Make sure the power supply is off, then remove the front panel and right side panel. 2) Close the condenser water supply line shut-off valve. If connected to a closed loop system, also close the condenser return line shut-off valve.
VII. Disposal The appliance contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certified service personnel.
We reserve the right to make changes in specifications and design without prior notice. A. Specification and Performance Data Sheets Pressure data is recorded at 5 min. into freezing cycle. The data not in bold should be used for reference only. 1. KMD-460MAH Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 10.0 A ( 5 Min.
2. KMD-460MWH Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.5A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 800(4.11) 770(3.67) WATER gal./24HR (gal./100 lbs.) 79(16.9)
6. KML-250MAH Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.2A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 813 (8.2) 755 (5.9) WATER gal./24HR (gal./100 lbs.) 84 (35.2) 194 (63.1)
7. KML-250MWH Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.5 A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 0 (0.00) 0 (0.0) WATER gal./24HR (gal./100 lbs.) 252 (0.0) 21 (284.0)
8. KML-351MAH Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.4 A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 750(6.4) 70/21(0.0) WATER gal./24HR (gal./100 lbs.) 57(20.3) 10(0.0) ICE PRODUCTION PER CYCLE...
9. KML-351MWH Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.5 A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 690 (5.41) 710 (4.85) WATER gal./24HR (gal./100 lbs.) 63 (20.5) 102 (29.2)
10. KML-451MAH Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 9.5 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 890 (6.1) 770 (4.6) WATER gal./24HR (gal./100 lbs.)
11. KML-451MWH Specification Sheet AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 9.8 A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 950 (5.5) 920 (5.3) POTABLE WATER gal./24HR (gal./100 lbs.) 87 (20.9) 124 (29.9)
12. KML-631MAH Specification Sheet AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 8.1 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC...
13. KML-631MWH Specification Sheet AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 8.0 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.)
14. KML-631MRH Specification Sheet AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V) AMPERAGE 7.6 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC...