Hoshizaki KMD-201AWA Service Manual
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Hoshizaki KMD-201AWA Service Manual

Hoshizaki KMD-201AWA Service Manual

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Direktlink Hoshizaki Crescent-Eisbereiter KMD201AA Bubble Tea zu Kälte-Berlin
Kälte-Berlin
Inh.: Christian Berg
Am Pfarracker 41
12209 Berlin
Fon: +49 (0) 30 / 74 10 40 22
Fax: +49 (0) 30 / 74 10 40 21
eMail: info@kaelte-berlin.de
Internet: http://www.kaelte-berlin.com
MODULAR CRESCENT CUBER
MODEL
HOSHIZAKI
KMD-201AA
KMD-201AWA
KMD-270AA
KMD-270AWA
SERVICE MANUAL
NO.
F049-817
ISSUED: SEP. 30, 2010
REVISED: JUN. 15, 2012

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  • Page 1 Direktlink Hoshizaki Crescent-Eisbereiter KMD201AA Bubble Tea zu Kälte-Berlin Kälte-Berlin Inh.: Christian Berg Am Pfarracker 41 NO. F049-817 12209 Berlin ISSUED: SEP. 30, 2010 Fon: +49 (0) 30 / 74 10 40 22 Fax: +49 (0) 30 / 74 10 40 21 REVISED: JUN. 15, 2012 eMail: info@kaelte-berlin.de...

  • Page 2: Table Of Contents

    PAGE I. SPECIFICATIONS--------------------------------------------------------------------------------------- 1 1. DIMENSIONS/SPECIFICATIONS --------------------------------------------------------------- 1 [a] KMD-201AA (air-cooled)------------------------------------------------------------------------ 1 [b] KMD-201AWA (water-cooled) ----------------------------------------------------------------- 2 [c] KMD-270AA (50Hz) (air-cooled) -------------------------------------------------------------- 3 [d] KMD-270AA (60Hz) (air-cooled) -------------------------------------------------------------- 4 [e] KMD-270AWA (50Hz) (water-cooled) ------------------------------------------------------- 5 [f] KMD-270AWA (60Hz) (water-cooled) -------------------------------------------------------- 6 II.
  • Page 3 [c] LOW ICE PRODUCTION ----------------------------------------------------------------------37 [d] ABNORMAL ICE---------------------------------------------------------------------------------38 [e] OTHER ---------------------------------------------------------------------------------------------38 V. REMOVAL AND REPLACEMENT-----------------------------------------------------------------39 1. SERVICE FOR REFRIGERANT LINES --------------------------------------------------------39 [a] SERVICE INFORMATION ---------------------------------------------------------------------39 [b] REFRIGERANT RECOVERY-----------------------------------------------------------------40 [c] EVACUATION AND RECHARGE------------------------------------------------------------40 2. BRAZING -----------------------------------------------------------------------------------------------41 3. COMPRESSOR ---------------------------------------------------------------------------------------41 4. DRIER ---------------------------------------------------------------------------------------------------42 5.

  • Page 4: Specifications

    I. SPECIFICATIONS 1. DIMENSIONS/SPECIFICATIONS [a] KMD-201AA (air-cooled)

  • Page 5: [B] Kmd-201Awa (Water-Cooled)

    [b] KMD-201AWA (water-cooled)

  • Page 6: [C] Kmd-270Aa (50Hz) (Air-Cooled)

    [c] KMD-270AA (50Hz) (air-cooled)

  • Page 7: [D] Kmd-270Aa (60Hz) (Air-Cooled)

    [d] KMD-270AA (60Hz) (air-cooled)

  • Page 8: [E] Kmd-270Awa (50Hz) (Water-Cooled)

    [e] KMD-270AWA (50Hz) (water-cooled)

  • Page 9: [F] Kmd-270Awa (60Hz) (Water-Cooled)

    [f] KMD-270AWA (60Hz) (water-cooled)

  • Page 10: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION Water Supply Tube [a] KMD-201/270AA Drain Valve Water Supply Inlet Spray Guide Hot Gas Valve Spray Tube Access Valve (High Side) Condenser * Not provided for later production Thermistor Expansion Valve Access Valve (Low Side) Fan Motor Compressor Cube Guide...

  • Page 11: [B] Kmd-201/270Awa

    [b] KMD-201/270AWA Water Supply Tube Drain Valve Water Supply Inlet Spray Guide Hot Gas Valve Spray Tube Access Valve (High Side) Water Regulator * Not provided for later production Thermistor Expansion Valve Access Valve (Low Side) Condenser Compressor Cube Guide Drier Water Tank Pump Motor...

  • Page 12: Sequence Of Operation

    2. SEQUENCE OF OPERATION The steps in the sequence are as outlined below. When power is supplied, a 5 second delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is 5, 6, 8, 9, 4, 7.

  • Page 13: [E] Normal Harvest Cycle

    [e] NORMAL HARVEST CYCLE LEDs 5, 6, and 8 are on. Comp continues to run, HGV remains open and HWV opens. As the evaporator warms, the thermistor reaches 9°C. The control board then receives the thermistor’s 3.9kΩ signal and starts the harvest timer. HWV is open during harvest for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 &...

  • Page 15: Control Board

    3. CONTROL BOARD * A HOSHIZAKI exclusive solid-state control is employed in KMD-201/270AA and KMD-201/270AWA Crescent Cubers. * All models are pretested and factory-adjusted. CAUTION 1. Fragile, handle very carefully. 2. A control board contains integrated circuits, which are susceptible to failure due to static discharge.

  • Page 16: [A] Control Board Layout

    [a] CONTROL BOARD LAYOUT #4 Harvest Water Valve #5 Freeze Water Valve #1, 2, 3 Float Switch Control Board Model KMD-201AA/AWA KMD-270AA/AWA P01771-02 Auxiliary Code V1 or Earlier V2 or Later V1 or Later Part Number P00013-02 P01771-02 P01771-02 Type HKM2006V003...

  • Page 17: [B] Features

    [b] FEATURES a) Maximum Water Supply Period - 6 minutes The harvest water valve will be open during harvest for 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 & 8), whichever is shorter. b) Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest cycle takes more than 20 minutes to complete.
  • Page 18 f) LED Lights and Audible Alarm Safeties The control board includes LED indicator lights, audible alarm safeties, and an output test feature. The "POWER OK" LED indicates control voltage and will remain on unless a control voltage problem occurs. The “POWER OK” LED flashes continuously when the bin is full and DV energizes for a maximum of 5 minutes to drain the water tank.

  • Page 19: [C] Controls And Adjustments

    [c] CONTROLS AND ADJUSTMENTS a) Default Dip Switch Settings The dip switch is factory-adjusted to the following positions: S1 Dip Switch No. KMD-201AA (50Hz) KMD-201AA (60Hz) KMD-201AWA (50Hz) KMD-201AWA (60Hz) KMD-270AA (50Hz) KMD-270AA (60Hz) KMD-270AWA (50Hz) KMD-270AWA (60Hz) S2 Dip Switch * Functions of S2 dip switch nos.
  • Page 20 Do not adjust the S2 dip switch. These must be left in the factory default position, or the unit will not operate properly. b) Harvest Timer (S1 dip switch 1 & 2) Used for adjustment of the harvest timer. The harvest timer starts counting when the thermistor reads a certain temperature at the evaporator outlet.
  • Page 21 e) Water Saver Timer (S1 dip switch 7 & 8) The water saver timer allows the water valve to close and the pump motor to circulate water in the tank during the final part of harvest. The water valve is open during harvest for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (determined by the water saver timer setting), whichever is shorter.
  • Page 22 Refill Counter (S2 dip switch 2, 3, & 4) [Program Ver. 2.5 or earlier] Do not adjust. These must be left in the factory default position or the unit will not operate properly. The KMD-201AA and KMD-201AWA refill 1 time. i) Factory Use (S2 Dip Switch 5) [Program Ver. 2.5 or earlier] Must remain off.
  • Page 23 m) Harvest Completion Detection Control (S2 dip switch 4) [Program Ver. 3.1, Ver. 3.2] Do not adjust. This must be left in the factory default position or the unit will not operate properly. It is deactivated on the KMD-201 series and activated on the KMD-270 series. When activated, this control determines whether ice remains on the evaporator at the end of a harvest cycle and at the beginning of a freeze cycle.

  • Page 24: [D] Control Board Check Procedure

    S2 Dip Switch Setting Anti-Slush Control No. 6 Activated (Ver. 2.0) Deactivated p) Anti-Slush Control (S2 dip switch 6) [Program Ver. 3.2] Do not adjust. This must be left in the factory default position or the unit will not operate properly.

  • Page 25: Harvest Control - Thermistor

    4. HARVEST CONTROL – THERMISTOR A thermistor (semiconductor) is used as a harvest control sensor, anti-slush sensor, and overfreeze sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the harvest timer, to momentarily stop the pump motor during the freeze cycle, or to extend the harvest cycle time.

  • Page 26: Float Switch

    5. FLOAT SWITCH [a] EXPLANATION OF OPERATION The float operates 2 switches within the float switch. The lower switch (black and blue wires) is used for low water safety protection, initiating the freeze cycle refill and terminating the freeze cycle. The upper switch (black and red wires) is used to terminate the freeze cycle refill only.

  • Page 27: Bin Control

    6. BIN CONTROL This machine uses a lever-actuated proximity switch (mechanical bin control) to control the ice level in the storage bin. No adjustment is required. [a] EXPLANATION OF OPERATION The bin control is connected to the K1 connector (pins 4 & 5) on the control board. When the bin control is calling for ice (proximity switch closed;...

  • Page 28: Switches

    7. SWITCHES Two different control switches are used for operation of KMD-201/270AA and KMD-201/270AWA. These switches are referred to as the "control switch" and the "service switch" and are located on the control box. [a] CONTROL SWITCH This switch is used to place the machine into one of three modes: “OFF” (center position), “ICE”...

  • Page 29: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT...

  • Page 30: Wiring Diagram

    2. WIRING DIAGRAM [a] KMD-201AA, KMD-201AWA P00034-01 only * The magnetic contactor wiring depends on the contactor model. P00819-01 P01694-01 P00034-01 VC20-1a1b-AC230V-N FC-0TUL G7L-1A-TUB See above...

  • Page 31: [B] Kmd-270Aa, Kmd-270Awa (50Hz)

    [b] KMD-270AA, KMD-270AWA (50Hz)

  • Page 32: [C] Kmd-270Aa, Kmd-270Awa (60Hz)

    [c] KMD-270AA, KMD-270AWA (60Hz)

  • Page 33: Timing Chart

    3. TIMING CHART [a] KMD-201AA, KMD-201AWA...

  • Page 34: [B] Kmd-270Aa, Kmd-270Awa

    [b] KMD-270AA, KMD-270AWA...

  • Page 35: Service Diagnosis

    IV. SERVICE DIAGNOSIS 1. 10-MINUTE DIAGNOSTIC PROCEDURE The 10 minute check out procedure is basically a sequence check which can be used at unit start-up or for system diagnosis. Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 21°C or warmer air and 10°C or warmer water temperatures.
  • Page 36 a. Lower Float Switch 1st Activation: Refill – The refill can occur at any time during the freeze cycle (1 refill per cycle). As ice builds the water level drops in the reservoir and the lower float switch activates (opens). LED 5 comes on and the control board energizes the fill water valve.

  • Page 37: Diagnostic Charts

    2. DIAGNOSTIC CHARTS [a] NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker will a) Power Supply 1. Off, blown fuse, or 1. Turn on, replace, or not start. tripped breaker. reset. 2. Loose connection. 2. Tighten. 3. Bad contacts. 3.
  • Page 38 PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker will k) Harvest Water Valve 1. Mesh filter or orifice gets 1. Clean not start. clogged and water (continued) supply cycle does not finish. 2. Coil winding opened. 2. Replace. 3. Wiring to water valve. 3.

  • Page 39: [B] Evaporator Is Frozen

    PROBLEM POSSIBLE CAUSE REMEDY [6] Freeze cycle time a) Drain Valve 1. Leaking by. 1. Clean or replace. is too short. b) Bloat Switch 1. Dirty or erratic operation. 1. Clean or replace. c) Control Board 1. Defective. 1. See "II. 3. [d] Control Board Check Procedure."...

  • Page 40: [C] Low Ice Production

    PROBLEM POSSIBLE CAUSE REMEDY [2] All ice formed on a) Evaporator 1. Scaled up. 1. Clean. evaporator does b) Water Supply Line 1. Water pressure too low. 1. Check and get not fall into bin in recommended harvest cycle. pressure. c) Water Filter System 1.

  • Page 41: [D] Abnormal Ice

    PROBLEM POSSIBLE CAUSE REMEDY [2] Harvest cycle a) See chart [b] [2] and check evaporator, water supply line, harvest water valve, time is long. ambient and/or water temperature, line valve (if applicable), thermistor, control board, and hot gas valve. [d] ABNORMAL ICE PROBLEM POSSIBLE CAUSE REMEDY...

  • Page 42: Removal And Replacement

    V. REMOVAL AND REPLACEMENT 1. SERVICE FOR REFRIGERANT LINES [a] SERVICE INFORMATION 1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R404A] The compressor must not be opened more than 15 minutes in replacement or service. Do not mix lubricants of different compressors even if both are charged with the same refrigerant, except when they use the same lubricant.

  • Page 43: [B] Refrigerant Recovery

    7) Evacuation, Vacuum Pump and Refrigerant Charge [R404A] Never allow the oil in the vacuum pump to flow backward. The vacuum level and vacuum pump may be the same as those for the current refrigerants. However, the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for R404A.

  • Page 44: Brazing

    2. BRAZING DANGER 1. Refrigerant R404A itself is not explosive or poisonous. However, when exposed to high temperatures (open flames), R404A can be decomposed to form hydrofluoric acid and carbonyl fluoride both of which are hazardous. 2. Always recover the refrigerant and store it in a proper container. Do not discharge the refrigerant into the atmosphere.

  • Page 45: Drier

    15) Connect the terminals and replace the terminal cover in its correct position. 16) Replace the panels and water tank in their correct positions. 17) Turn on the power supply. Note: Hoshizaki recommends that compressor starting electrics are always replaced at the same time as the compressor. 4. DRIER IMPORTANT Always install a new drier every time the sealed refrigeration system is opened.

  • Page 46: Hot Gas Valve

    5) Remove the drier using brazing equipment. 6) Braze the new drier, with the arrow on the drier in the direction of the refrigerant flow. Use nitrogen gas at a pressure of 20 to 30 kPa when brazing tubings. Braze in an access valve using a tee if necessary.

  • Page 47: Expansion Valve

    8) Install the new drier (see "V. 4. DRIER"). 9) Check for leaks using nitrogen gas (970 kPa) and soap bubbles. 10) Evacuate the system and charge it with refrigerant (see "V. 1. [c] EVACUATION AND RECHARGE"). 11) Attach the solenoid coil to the valve body, and secure it with the screw. 12) Connect the lead wires.

  • Page 48: Evaporator

    9) Evacuate the system, and charge it with refrigerant. For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. 10) Attach the expansion valve bulb to the suction line in the same location as the previous bulb. The bulb should be at the 12 o'clock position on the tube. Be sure to secure the bulb with the clamp and holder and to insulate it.

  • Page 49: Water Regulating Valve - Water-Cooled Model Only

    13) Replace the insulation and the panels in their correct positions. 14) Turn on the power supply. 8. 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.

  • Page 50: Adjustment Of Water Regulating Valve - Water-Cooled Model Only

    17) Check for water leaks. 18) Replace the panels in their correct positions. 19) Turn on the power supply. 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.

  • Page 51: Pump Motor

    7) Replace the panels in their correct positions. Screw Screw 8) Turn on the power supply. (Remove) (Loosen) Screw Fan Motor Fan Motor Bracket Fan Blade Cover 11. PUMP MOTOR 1) Turn off the power supply. 2) Remove the panels and front insulation. 3) Disconnect the connector of the pump motor lead.

  • Page 52: Water Valve

    7) Remove the hose band connecting the discharge outlet and pull off the rubber hose. 8) Install the new motor in the reverse order of the removal procedure. 9) Replace the panels and front insulation in their correct positions. 10) Turn on the power supply. 12.

  • Page 53: Water Tank

    7) Remove the two mounting screws. 8) Install the new valve in the reverse order of the removal procedure. 9) Open the water supply tap. 10) Plug in the icemaker or connect the power source. 11) Check for leaks. 12) Refit the panels in their correct positions. 14.

  • Page 54: Float Switch

    9) Install the new water tank in the reverse order of the removal procedure. 10) Refit the panels in their correct positions. 11) Turn on the power supply. 15. FLOAT SWITCH 1) Remove the pump motor bracket. See "V. 14. WATER TANK." 2) Pull up the pump motor bracket from the water tank.

  • Page 55: Bin Control Switch

    4) (KMD-270 series only) Remove the two mounting screws, and release the Screws float switch from the tabs on the bracket. Float Switch 5) Install the new float switch in the reverse order of the removal procedure. Packing 6) Refit the panels in their correct positions. Bracket 7) Turn on the power supply.
  • Page 56 7) While pulling up the bin control lead, hook the bin control on the right side interior wall. Then push the bin control up against the bottom of the unit, and slide to the back until it snaps in place. Make sure the slotted holes at the right side of the bin control are securely placed on the collars at the bottom of the unit.

  • Page 57: Thermistor

    17. THERMISTOR 1) Turn off the power supply. 2) Remove the panels. 3) Disconnect the connector of the thermistor lead (orange). 4) Remove the ties, insulation, thermistor holder, and thermistor in this order. 5) Remove the old sealant from the thermistor holder and suction pipe. 6) Wipe off any moisture or condensation from the suction pipe surfaces.

  • Page 58: Control Box

    18. CONTROL BOX 1) Turn off the power supply. 2) Remove the front panel. 3) Remove the one mounting screw, and pull the control box cover. 4) Remove the two mounting screws, and pivot the control box to the left side slightly and pull the control box towards you if needed.

  • Page 59: [A] Control & Service Switch

    Note: After replacing the components inside the control box, connect and tie the wires properly in their correct position. Especially make sure that the harness does not press the push buttons on the control board. Control Switch Control Board Service Switch Noise Suppression Capacitor Fuse Fuse Holder...

  • Page 60: [D] Control Board

    [d] CONTROL BOARD 1) Disconnect all the connectors. 2) Remove the four board supports secured to the control box to release the control board. 3) Install the new control board in the reverse order of the removal procedure. 4) Check the dip switch for proper setting. 5) When reconnecting the connectors, do not push them too hard.

  • Page 61: [J] Capacitor For Pump Motor

    2) Install the new run capacitor in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [j] CAPACITOR FOR PUMP MOTOR 1) Disconnect the tab terminals, remove the screw. 2) Install the new capacitor in the reverse order of the removal procedure.
  • Page 62 10) Pull off the spray guide from the evaporator. Spray Guide 11) Refit the removed parts in the reverse order of the removal procedure. Check for water leaks. IMPORTANT Fit the spray guide securely and tightly on the evaporator fin. Otherwise, cloudy or irregular ice cubes or performance reduction may be caused.

  • Page 63: Cleaning And Maintenance Instructions

    [a] CLEANING PROCEDURE 1) Dilute approximately 9.5 fl. oz. (281 ml) of recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 1.8 gallon (6.8 lit.) of water. 2) Remove all ice from the evaporator and the storage bin/dispenser unit.
  • Page 64 8) In bad or severe water conditions, clean the float switch as described below. Otherwise, continue to step 9. a. Loosen the two thumbscrews securing the pump motor bracket. b. Disconnect the discharge hose. c. Disconnect the pump motor connector and the float switch connector from the side of the control box.
  • Page 65 h. Replace the float switch in its correct position. i. Replace the removed parts in the reverse order of which they were removed. 9) Pour the cleaning solution into the water tank. 10) Move the service switch to the "WASH" position. 11) Replace the front insulation and the front panel in their correct positions.

  • Page 66: [B] Sanitizing Procedure

    32) Repeat steps 18 through 31 three more times to rinse thoroughly. Note: If you do not sanitize the icemaker, go to step 14 in "SANITIZING PROCEDURE." [b] SANITIZING PROCEDURE – FOLLOWING CLEANING PROCEDURE 1) Dilute a 5.25% sodium hypochlorite solution (chlorine bleach) with water (add approximately 0.9 fl.

  • Page 67: [A] Stainless Steel Exterior

    [a] STAINLESS STEEL EXTERIOR To prevent corrosion, wipe the exterior occasionally with a clean, soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. [b] STORAGE BIN AND SCOOP * Wash your hands before removing ice. Use the plastic scoop provided (bin accessory). * The storage bin/dispenser unit is for ice use only.
  • Page 68 2) Move the control switch on the control box to the "OFF" position. 3) Wait 3 minutes. 4) Move the control switch to the "ICE" position. 5) Replace the front panel in its correct position and turn on the power supply. 6) Allow 5 minutes for the icemaker to fill with water and the water pump to start operating.
  • Page 69 4) Turn off the power supply and remove the front panel. 5) Move the control switch to the "OFF" position. 6) Replace the front panel in its correct position. 7) Remove all ice from the storage bin/dispenser unit, and clean the storage bin/dispenser unit.

This manual is also suitable for:

Kmd-201aaKmd-270aaKmd-270awa

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