Hoshizaki KM-515MAH Service Manual
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Hoshizaki KM-515MAH Service Manual

Modular crescent cuber
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Modular Crescent Cuber
Models
KM-515MAH
KM-515MWH
KM-515MRH
SERVICE MANUAL
1
™
Number: 73157
Issued: 2-1-2008

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  • Page 1 Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber Models KM-515MAH KM-515MWH KM-515MRH SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com ™ Number: 73157 Issued: 2-1-2008...
  • Page 2 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, write, or send an e-mail message to the HOSHIZAKI Technical Support Department for assistance. HOSHIZAKI AMERICA, INC.

  • Page 3: Table Of Contents

    Please retain this booklet for any further reference that may be necessary. CONTENTS I. Specifications ........................5 A. Icemaker ........................5 1. KM-515MAH (air-cooled) ..................5 2. KM-515MWH (water-cooled) ................... 6 3. KM-515MRH (remote air-cooled) ................7 B. Condenser Unit ......................8 1. URC-5F ........................8 II.
  • Page 4 2. KM-515MWH (water-cooled) ................. 26 3. KM-515MRH (remote air-cooled) ................27 B. Wiring Diagrams ......................28 1. KM-515MAH (air-cooled) and KM-515MWH (water-cooled) ......... 28 2. KM-515MRH (remote air-cooled) ................29 C. Performance Data ....................... 30 1. KM-515MAH (air-cooled) ..................30 2.

  • Page 5: Specifications

    I. Specifications A. Icemaker 1. KM-515MAH (air-cooled) AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 11.7 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR.

  • Page 6: Km-515Mwh (Water-Cooled)

    2. KM-515MWH (water-cooled) AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 9.6 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *500 (227) 493 (223)

  • Page 7: Km-515Mrh (Remote Air-Cooled)

    3. KM-515MRH (remote air-cooled) AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 11.3A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *491 (223) 480 (218)

  • Page 8: Condenser Unit

    B. Condenser Unit 1. URC-5F 24" (610 mm) 23-1/32" (585 mm) 19-11/16" 6/16" × 3/4" (10×20 mm) (500 mm) 4×2 (SLOTTED HOLES) 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"...

  • Page 9: Specifications

    SPECIFICATION NO. 06A022 ISSUED: 10/12/2006 ITEM: HOSHIZAKI REMOTE CONDENSER UNIT Specifications MODEL URC-5F BEGINNING SERIAL NO. ________________ MODEL: URC-5F ENDING SERIAL NO. ___________________ AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR 115 V Total 1.3FLA EXTERIOR DIMENSIONS (WxDxH) 21-15/16" x 15-11/16" x 17-7/8" (557 x 398 x 454 mm) DIMENSIONS INCLUDING LEGS (WxDxH) 24"...

  • Page 10: General Information

    II. General Information A. Construction 1. KM-515MAH (air-cooled) Spray Tubes Water Supply Pipe Expansion Valve Bin Control Thermostat Condenser Hot Gas Valve Fan Motor Condenser Control Switch Liquid Line Valve Compressor Drier Float Switch Control Box Water Pump...

  • Page 11: Km-515Mwh (Water-Cooled)

    2. KM-515MWH (water-cooled) Water Supply Pipe Expansion Valve Spray Tubes Bin Control Thermostat Water Regulator Control Switch Hot Gas Valve Condenser Liquid Line Valve Drier Compressor Float Switch Control Box Water Pump...

  • Page 12: Km-515Mrh (Remote Air-Cooled)

    3. KM-515MRH (remote air-cooled) Expansion Valve Water Supply Pipe Spray Tubes Junction Box Hot Gas Valve Bin Control Thermostat Reciever Tank Control Switch Drier Compressor Liquid Line Valve Float Switch Control Box Water Pump...

  • Page 13: Sequence Of Operation

    B. Sequence of Operation The steps in the sequence are as outlined below. When power is supplied, the red "POWER OK" LED on the control board comes on. A 5-second delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is 1, 4, 3, 2. 1.

  • Page 14: Normal Harvest Cycle

    5. Normal Harvest Cycle LEDs 1, 4, and 2 are on. Comp, FMR, and HGV remain energized. PM stops and WV energizes. The control board monitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 48°F (9°C), the control board reads a 3.9 kΩ...

  • Page 16: Control Board

    C. Control Board • A HOSHIZAKI exclusive solid-state control is employed in KM-515MAH, KM-515MWH, and KM-515MRH Modular Crescent Cubers. • All models are pretested and factory-adjusted. CAUTION 1. Fragile, handle very carefully. 2. The control board contains integrated circuits, which are susceptible to failure due to static discharge.

  • Page 17: Control Board Layout

    1. Control Board Layout Control Products "E" Control Board Output Test Switch (used to test relays on board) S4 Dip Switch Alarm Reset Switch Backup Freeze Timer LED Connector K3 Harvest Control (thermistor) Backup Harvest Connector K4 Timer LED Open (not connected) Alarm Buzzer Microprocessor...

  • Page 18: Features

    2. Features a) Maximum Water Supply Period – Six minutes The inlet water valve will be open during harvest for six minutes or the length of harvest 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 19: F) Led Lights And Audible Alarm Safeties

    f) 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. A beep occurs when the power is turned off. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below.

  • Page 20: Controls And Adjustments

    Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. For more information, contact HOSHIZAKI Technical Support at 1-800-233-1940. a) Default S4 Dip Switch Settings The dip switches are factory-adjusted to the following positions: Dip Switch No.

  • Page 21: C) Pump-Out Timer (S4 Dip Switch 3 & 4)

    However, a setting longer than the factory setting may be advised in cases where the flush provided at harvest needs to be prolonged for extra cleaning. Before changing this setting, contact HOSHIZAKI Technical Support at 1-800-233-1940 for recommendations. Keep in mind that setting the pump-out timer's harvest timer (T2) to a longer setting will decrease 24 hour production.

  • Page 22: D) Pump-Out Frequency Control (S4 Dip Switch 5 & 6)

    d) Pump-Out Frequency Control (S4 dip switch 5 & 6) CAUTION Do not adjust. Adjustments to this setting may adversely affect performance and warranty coverage. The pump motor drains the water tank at the frequency set by the pump-out frequency control.

  • Page 23: Control Board Check Procedure

    4. Control Board Check Procedure Before replacing a control board 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. 1) Check the S4 dip switch settings to assure that #3, 4, 7, 8, 9, & 10 are in the factory default position.

  • Page 24: Harvest Control - Thermistor

    D. Harvest Control – Thermistor A thermistor (semiconductor) is used for a harvest control sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the harvest 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 25: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KM-515MAH (air-cooled)

  • Page 26: Km-515Mwh (Water-Cooled)

    2. KM-515MWH (water-cooled)

  • Page 27: Km-515Mrh (Remote Air-Cooled)

    3. KM-515MRH (remote air-cooled)

  • Page 28: Wiring Diagrams

    B. Wiring Diagrams 1. KM-515MAH (air-cooled) and KM-515MWH (water-cooled)

  • Page 29: Km-515Mrh (Remote Air-Cooled)

    2. KM-515MRH (remote air-cooled)

  • Page 30: Performance Data

    C. Performance Data 1. KM-515MAH (air-cooled) APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 90/32 lbs./day kg./day 100/38 APPROXIMATE ELECTRIC 70/21 1012 1038 CONSUMPTION 80/27 1005 1055 1071 1090 90/32 1012...

  • Page 31: Km-515Mwh (Water-Cooled)

    2. KM-515MWH (water-cooled) APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 90/32 lbs./day kg./day 100/38 APPROXIMATE ELECTRIC 70/21 CONSUMPTION 80/27 90/32 watts 100/38 APPROXIMATE WATER 70/21 1.95 2.10 3.05 CONSUMPTION PER 24 HR. 80/27 2.06 2.29...

  • Page 32: Km-515Mrh (Remote Air-Cooled)

    3. KM-515MRH (remote air-cooled) APPROXIMATE ICE WATER TEMP. (ºF/ºC) AMBIENT TEMP. PRODUCTION PER 24 HR. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 90/32 lbs./day kg./day 100/38 APPROXIMATE ELECTRIC 70/21 1000 1026 1058 CONSUMPTION 80/27 1020 1061 1091 90/32 1026 1090 1121 watts 100/38 1031...

  • Page 33: Service Diagnosis

    IV. Service Diagnosis A. 10-Minute KM 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 70°F (21°C) or warmer air and 50°F (10°C) or warmer water temperatures.
  • Page 34 5) Freeze Cycle – LED 1 is on. Compressor (and fan motor on a remote air-cooled unit) remains energized, pump motor, line valve (if applicable), and fan motor (self-contained air-cooled unit) energize. The inlet water valve and hot gas valve de-energize. The unit is held in freeze by a 5 minute short cycle protection timer.

  • Page 35: Diagnostic Charts

    B. Diagnostic Charts 1. No Ice Production Problem Possible Cause Remedy [1] The icemaker will not a) Power Supply 1. Off, blown fuse, or 1. Turn on, replace, or reset. start. tripped breaker. 2. Loose connection. 2. Tighten. 3. Bad contacts. 3.
  • Page 36 Problem Possible Cause Remedy [1] The icemaker will not g) Transformer 1. Coil winding opened 1. Replace. start. (continued) or shorted. h) Wiring to Control Board 1. Loose connections or 1. Check for continuity and open. replace. i) Interlock Switch 1.
  • Page 37 Problem Possible Cause Remedy [3] Compressor will d) Starter 1. Bad contacts. 1. Check and replace. not start or stops 2. Coil winding opened. 2. Replace. operating. (continued) e) Compressor 1. Power supply not 1. Refer to nameplate and within specifications. correct.

  • Page 38: Evaporator Is Frozen Up

    Problem Possible Cause Remedy [8] All components a) Refrigerant 1. Low charge. 1. Check for leaks and run, but no ice is recharge. produced. 2. Air or moisture 2. Replace drier and trapped. recharge. b) Compressor 1. Defective valve. 1. Replace. c) Hot Gas Valve 1.
  • Page 39 Problem Possible Cause Remedy [2]All ice formed on a) Evaporator 1. Scaled up. 1. Clean. evaporator does not b) Water Supply Line 1. Water pressure too 1. Check and get fall into bin in harvest low. recommended pressure. cycle. c) Water Filter System 1.

  • Page 40: Low Ice Production

    3. Low Ice Production Problem Possible Cause Remedy [1] Freeze cycle time is a) See chart 2.[1] and check float switch, inlet water valve, control board, water long. pump, spray tubes, evaporator, and expansion valve. b) See chart 1.[1] and check dirty air filter or condenser, ambient or water temperature, refrigerant charge, water pressure, and condenser water regulating valve (water-cooled model only).

  • Page 41: Other

    5. Other Problem Possible Cause Remedy [1] Icemaker will not stop a) Bin Control Thermostat 1. Set too cold. 1. See "II.E. Bin Control." when bin is filled with 2. Defective. 2. Replace. ice. [2] Abnormal noise. a) Pump Motor 1.

  • Page 42: Removal And Replacement Of Components

    V. Removal and Replacement of Components IMPORTANT 1. Ensure all components, fasteners, and thumbscrews are securely in place after the equipment is serviced. 2. 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 43: Evacuation And Recharge (R-404A)

    For air-cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled models, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No. 700-88 be used.

  • Page 44: Removal And Replacement Of Compressor

    B. 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 45: Removal And Replacement Of Expansion Valve

    C. Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigeration 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 46: Removal And Replacement Of Hot Gas Valve Or Line Valve

    D. Removal and Replacement of Hot Gas Valve or Line Valve IMPORTANT 1. Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced. 2. Always install a new drier every time the sealed refrigeration system is opened.

  • Page 47: Removal And Replacement Of Evaporator

    E. 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 replacement have been made. 1) Turn off the power supply. 2) Remove the panels and the front and top insulation.

  • Page 48: Adjustment Of Water Regulating Valve - Water-Cooled Model Only

    4) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve. 5) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out.

  • Page 49: Removal And Replacement Of Headmaster (Condensing Pressure Regulator - C

    H. Removal and Replacement of Headmaster (Condensing Pressure Regulator - C.P.R.) - Remote Air-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.

  • Page 50: Removal And Replacement Of Thermistor

    I. Removal and Replacement of Thermistor IMPORTANT 1. Fragile, handle very carefully. 2. Always use the 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 the recommended foam insulation (non-absorbent type) or equivalent.

  • Page 51: Removal And Replacement Of Fan Motor

    J. Removal and Replacement of Fan Motor Note: When replacing a fan motor with defective winding, it is recommended that a new capacitor be installed. 1) Turn off the power supply. 2) Remove the panels. 3) Remove the junction box cover from the remote condenser unit (remote air-cooled model).

  • Page 52: Removal And Replacement Of Pump Motor

    L. Removal and Replacement of Pump Motor 1) Turn off the power supply. 2) Remove the front panel. 3) Remove the base cover. 4) Drain the water tank by removing one end of the pump tubing. See Fig. 3. 5) Disconnect the pump suction and discharge hoses. 6) Remove the closed end connectors from the pump motor leads.

  • Page 53: Cleaning And Maintenance

    Ensure all components, fasteners, and thumbscrews are securely in place after any cleaning or maintenance is done to the equipment. A. Cleaning and Sanitizing Instructions HOSHIZAKI recommends cleaning this icemaker at least once a year. More frequent cleaning, however, may be required in some existing water conditions. WARNING 1.

  • Page 54: Cleaning Procedure

    1. Cleaning Procedure 1) Dilute 16 fl. oz. (473 ml) of Hoshizaki "Scale Away" with 3 gal. (11 l) of warm water. 2) Remove all ice from the evaporator and the storage bin. Note: To remove cubes on the evaporator, turn off the power supply and turn it back on after 3 minutes.

  • Page 55: Sanitizing Procedure - Following Cleaning Procedure

    20) Remove the front panel and fully open the cleaning valve. 21) Move the control switch to the "WASH" position. 22) Replace the front panel in its correct position. 23) Turn on the power supply to rinse off the cleaning solution. 24) Turn off the power supply after 5 minutes.

  • Page 56: Maintenance

    B. 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, soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. 2.
  • Page 57 5) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out. 6) Close the condenser water supply line drain valve and replace the right side panel in its correct position.

This manual is also suitable for:

Km-515mwhKm-515mrh

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