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Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber Models KM-320MAH, MWH KM-515MAH, MWH, MRH KM-600MAH KM-650MAH, MWH(-M), MRH KM-901MAH, MWH, MRH/3 SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com Number: 73196 Issued: 4-29-2013...
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Hoshizaki provides this manual primarily to assist qualified service technicians in the service of the appliance. 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. Phone: 1-800-233-1940; (770) 487-2331 Fax: 1-800-843-1056;...
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 ....................
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 • The appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. •...
I. Construction and Water/Refrigeration Circuit Diagram A. Construction 1. Air-Cooled Models (MAH) Thermostatic Expansion Valve Water Supply Inlet Spray Tubes Hot Gas Valve Inlet Water Valve Thermostatic Bin Control Condenser Cleaning Valve Fan Motor Control Switch High-Pressure Switch Drier Float Switch Liquid Line Valve KM-515MAH Water Pump...
2. Water-Cooled Models (MWH(-M)) Thermostatic Main Transformer Expansion Valve KM-650MWH-M Water Supply Inlet Spray Tubes Hot Gas Valve Inlet Water Valve High-Pressure Switch Water Regulating Thermostatic Valve Bin Control Condenser Cleaning Valve Control Box Control Switch Liquid Line Valve KM-320MWH and Float Switch KM-515MWH Drier...
3. Remote Models (MRH/3) Thermostatic Expansion Valves Spray Tubes Water Supply Inlet Inlet Water Valve Hot Gas Valve Cleaning Valve Junction Boxes Control Switch Control Box Thermostatic Bin Control Receiver Tank Float Switch Water Pump Drier Compressor Liquid Line Valve Mechanical Bin Control and Bracket Thermostatic Bin Control Bracket &...
B. Water/Refrigeration Circuit Diagram 1. Air-Cooled Models (MAH) Spray Tubes Condenser Inlet Water Valve Drier High-Pressure Evaporator Water Supply Switch Liquid Line Valve (KM-515MAH) Heat Thermistor Exchanger Suction Line Strainer Water Pump Float Switch Hot Gas Water Valve Tank Discharge Line Compressor Pump Out Freeze...
2. Water-Cooled Models (MWH(-M)) Water Regulating Valve Condenser Spray Tubes Inlet Water Valve Drier Evaporator Water Supply Liquid Line Valve (KM-320MWH and KM-515MWH) Heat Thermistor Exchanger High-Pressure Switch Suction Line Strainer Water Pump Float Switch Hot Gas Water Valve Tank Discharge Line Compressor Freeze...
II. Sequence of Operation and Service Diagnosis A. Sequence of Operation Flow Chart 1. "E" and "G" Control Board without Harvest Pump Timer Operation...
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. "E" and "G" Control Board without Harvest Pump Timer Diagnosis 3) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5-sec. delay occurs. • "E" Control Board: CB red "POWER OK" LED turns 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."...
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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 (R) 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. "E" CB first pump-out is after the first freeze cycle. "G" CB first pump-out is determined by S4 dip switch 5 & 6. See the table below. "E"...
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9) Shutdown a) "E" Control Board: Thermostatic Bin Control (TBC): When the appliance is running, hold ice in contact with the thermostatic bulb. TBC 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 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. If harvest cycle begins (Comp, HGV, FMR energized), 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 3 turns on and PM energizes.
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6) Freeze Cycle – LED 1 is on. Comp, FMR, and PM continue. FM and LLV energize. HGV and X10 relay de-energize. Appliance is held in freeze by a 5-min. short cycle protection timer. After 5-min. timer terminates and FS opens, freeze cycle terminates. Note: PM power supply switches from CB K1 #5 (DBU) in harvest to K1 #4 (R) in freeze.
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f) Refrigerant Pressures, HM, and TXV Diagnosis: If evaporator is still not cooling, check refrigerant pressures. See "VIII.B. Performance Data." Next, check HM operation. If refrigeration pressures are above HM setpoint and HM is bypassing, replace HM. Check TXV for proper operation. Remove TXV bulb and hold it in your hand, refrigerant low-side pressure should rise, place TXV bulb in ice water, refrigerant low-side pressure should drop.
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is complete. The pump-out frequency control (S4 dip switch 5 & 6) is factory set, and generally no adjustment is required. However, the pump-out frequency control can be set to have a pump-out occur every cycle, or every 2, 5, or 10 cycles. For details, see "III.C.4.
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 This appliance uses a lever-actuated proximity switch to control the ice level in the storage bin. No adjustment is required. To check TBC, 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.
6) Wipe down FS housing, shaft, float, and retainer rod with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Clean the inside of the rubber boot and hose with cleaning solution.
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. Main Transformer a) Voltage tap switch not set to proper voltage. (3 phase and KM-650MWH-M b) Coil winding open or shorted.
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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 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. 2. Spray Tubes and/or Spray a) Dirty. Guides b) Out of position.
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Low Ice Production - Possible Cause 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. and Cleaning" c) Defective switch. 3. Inlet Water Valve a) Leaking by. 4.
III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KM 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 1. "E" Control Board "E" Control Board • "OUTPUT TEST" Button • "ALARM RESET" Button • S4 Dip Switch (used to test relays on control board) • Freeze Timer • K3 (white) Connector LED (yellow) Thermistor (harvest control and high temperature safety) •...
2. "G" Control Board "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 1. "E" Control Board At startup, a 5-second delay occurs while the control board conducts an internal timer check. A beep occurs when power is turned off. The red "POWER OK" LED indicates proper control voltage and remains on unless a control voltage problem occurs.
2. "G" Control Board 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.
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 for both the "E" and "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) NOTICE Do not adjust on KM-515M_H without harvest pump timer. Adjustments to this setting on KM-515M_H without harvest pump timer may adversely affect performance and warranty coverage. The pump-out frequency control is factory set to drain the water tank every 10 cycles on all KM-320M_H, KM-600MAH, KM-650M_H, KM-901M_H/3 and on KM-515MAH with harvest pump timer, and every cycle on KM-515M_H without harvest pump timer.
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.
8. Float Switch Selector (S5 dip switch 1): "G" Control Board NOTICE Do not adjust. This must be left in the factory default position or the icemaker will not operate correctly. 9. Refill Counter (S5 dip switch 2 through 5): "G" Control Board NOTICE Do not adjust.
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 ARI 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. • To prevent damage to the water pump, do not operate the appliance with the control switch in the "WASH"...
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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.
VIII. Technical Information A. Specification Sheets 1. KM-320MAH AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 9.7 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.
2. KM-320MWH AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.2 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 ) *352 (160) 348 (158) 324 (147)
3. KM-515MAH 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. Temp.(°F) lbs./day ( kg/day ) *501 (227) 482 (218) 447 (203)
4. KM-515MWH 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) 481 (218) 465 (211)
5. KM-515MRH 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) 443 (201) Reference without *marks...
6. KM-600MAH AC SUPPLY VOLTAGE 115-120/60/1 AMPERAGE 12.0 A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *592 (269) 566 (257) 516 (234)
7. KM-650MAH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire for 115V) AMPERAGE 7.2 A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *661 (300) 632 (287)
8. KM-650MWH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire for 115V) AMPERAGE 5.4 A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *661 (300) 649 (294)
10. KM-650MRH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire for 115V) AMPERAGE 7.4 A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *632 (287) 612 (278)
11. KM-901MAH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire for 115V) AMPERAGE 11.4 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 ) *874 (396) 832 (378)
12. KM-901MWH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire for 115V) AMPERAGE 8.7A (5 Min. Freeze AT 104°F/WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A MAXIMUM FUSE SIZE 15 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR. Temp.(°F) lbs./day ( kg/day ) *912 (414) 887 (402) 849 (385)
13. KM-901MRH AC SUPPLY VOLTAGE 208-230/60/1 (3 wire for 115V) AMPERAGE 11.6A (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 ) *889 (403) 859 (389) 803 (364)
14. KM-901MRH3 AC SUPPLY VOLTAGE 208-230/60/3 AMPERAGE 7.0A (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 ) *899 (408) 874 (397) 817 (371) Reference without *marks...
9. KM-650MWH-M AWAITING DATA Note: 1. Pressure data is recorded at 5 min. into freezing cycle. The data not in bold should be used for reference only. 2. We reserve the right to make changes in specifications and design without prior notice.