Hoshizaki F043-809 KMD-410MAH Service Manual
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Hoshizaki F043-809 KMD-410MAH Service Manual

Modular crescent cuber
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Summary of Contents for Hoshizaki F043-809 KMD-410MAH

  • Page 1 02'8/$5 &5(6&(17 &8%(5 02'(/ 6(59,&( 0$18$/ +26+,=$., .0'0$+ .0'0:+ ) ,668(' -81   5(9,6(' -81  ...

  • Page 3: Table Of Contents

    I. SPECIFICATIONS--------------------------------------------------------------------------------------- 1 1. SPECIFICATIONS----------------------------------------------------------------------------------- 1 [a] KMD-410MAH (air-cooled) --------------------------------------------------------------------- 1 [b] KMD-410MWH (water-cooled) ---------------------------------------------------------------- 2 II. GENERAL INFORMATION--------------------------------------------------------------------------- 3 1. CONSTRUCTION------------------------------------------------------------------------------------ 3 [a] KMD-410MAH ------------------------------------------------------------------------------------- 3 [b] KMD-410MWH ------------------------------------------------------------------------------------ 4 2. SEQUENCE OF OPERATION-------------------------------------------------------------------- 5 [a] ONE MINUTE FILL CYCLE -------------------------------------------------------------------- 5 [b] INITIAL HARVEST CYCLE--------------------------------------------------------------------- 5 [c] FREEZE CYCLE ---------------------------------------------------------------------------------- 5 [d] DRAIN CYCLE ------------------------------------------------------------------------------------ 5...
  • Page 4 1. 10-MINUTE DIAGNOSTIC PROCEDURE -----------------------------------------------------27 2. DIAGNOSTIC CHARTS-----------------------------------------------------------------------------29 [a] NO ICE PRODUCTION ------------------------------------------------------------------------29 [b] EVAPORATOR IS FROZEN UP -------------------------------------------------------------32 [c] LOW ICE PRODUCTION ----------------------------------------------------------------------33 [d] ABNORMAL ICE---------------------------------------------------------------------------------33 [e] OTHER ---------------------------------------------------------------------------------------------34 V. REMOVAL AND REPLACEMENT-----------------------------------------------------------------35 1. SERVICE FOR REFRIGERANT LINES --------------------------------------------------------35 [a] SERVICE INFORMATION ---------------------------------------------------------------------35 [b] REFRIGERANT RECOVERY-----------------------------------------------------------------36 [c] EVACUATION AND RECHARGE------------------------------------------------------------36...

  • Page 5: Specifications

    I. SPECIFICATIONS 1. SPECIFICATIONS [a] KMD-410MAH (air-cooled) AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg/day) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER...

  • Page 6: [B] Kmd-410Mwh (Water-Cooled)

    [b] KMD-410MWH (water-cooled) AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day (kg/day) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) WATER COOLED CONDENSER...

  • Page 7: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION [a] KMD-410MAH Water Supply Tube Spray Guide Spray Tube Cleaning Valve Access Valve (High Side) Thermistor Access Valve (Low Side) Cube Guide Water Tank Pump Motor Float Switch Bin Control Switch Drain Valve Water Supply Inlet Hot Gas Valve Control Box Harvest Water Valve...

  • Page 8: [B] Kmd-410Mwh

    [b] KMD-410MWH Water Supply Tube Spray Guide Spray Tube Cleaning Valve Access Valve (High Side) Thermistor Access Valve (Low Side) Cube Guide Water Tank Pump Motor Float Switch Bin Control Switch Drain Valve Water Supply Inlet Hot Gas Valve Drier Control Box Harvest Water Valve Fill Water Valve...

  • Page 9: 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 10: [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 9ºC. The control board then receives the thermistor’s 3.9kŸ signal and starts the harvest timer. HWV is open during harvest for a maximum of 6 minutes or the length harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 &...

  • Page 12: Control Board

    3. CONTROL BOARD * A HOSHIZAKI exclusive solid-state control is employed in KMD-410MAH and KMD-410MWH Crescent Cubers. * All models are pretested and factory-adjusted. 1. Fragile, handle very carefully. 2. A control board contains integrated circuits, which are susceptible to failure due to static discharge.

  • Page 13: [A] Control Board Layout

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

  • Page 14: [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 S 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 15 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 16: [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-410MAH KMD-410MWH Control Board Program Ver. P00013-02 2.5 or earlier P01771-02 Do not adjust the S2 dip switch. These must be left in the factory default position, or the unit will not operate properly.
  • Page 17 c) Drain Timer (S1 dip switch 3 & 4) Once every ten freeze cycles, the drain valve opens to drain the water tank for the time determined by the drain timer. These switches also determine the time to delay completion of a defrost cycle, i.e.
  • Page 18 f) Freeze Timer (S1 dip switch 9 & 10) The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues. Upon termination of freeze timer, machine initiates the harvest cycle. After 2 consecutive timer terminations, machine will shut down, possibly indicating a problem. The freeze timer is factory adjusted, and no adjustment is required.
  • Page 19 S2 Dip Switch Setting Anti-Slush Control No. 6 Activated (Ver. 1.0) Control Board P01771-02 k) Harvest Promotion Control (S2 dip switch 2) [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.
  • Page 20 temperature at the end of a harvest cycle is 4K or more and if the temperature at the end of a harvest cycle is 48°F (9°C) or less, the harvest cycle is extended for 30 seconds. If the difference between the temperature at the beginning of a freeze cycle and the minimum temperature after 30 seconds in the freeze cycle is 2.5K or more and less than 3.5K, the next harvest cycle is extended for 30 seconds.

  • Page 21: [D] Control Board Check Procedure

    [d] 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 dip switch settings to assure that S1 dip switch 3, 4, 7, 8, 9, & 10 and S2 dip switch 1 through 6 are in the factory default position.

  • Page 22: 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 or momentarily stop the pump motor during the freeze cycle, or to extend the harvest cycle time.

  • Page 23: 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 24: 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 25: Switches

    7. SWITCHES Two different control switches are used for operation of KMD-410MAH and KMD-410MWH. 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 26: Technical Information

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

  • Page 27: Wiring Diagram

    2. WIRING DIAGRAM * The magnetic contactor wiring depends on the contactor model. 428393-01 VC20-1a1b 449000-01 G7L-1A-TUB See above 449000-01 only...

  • Page 28: Timing Chart

    3. TIMING CHART BOARD CONTROLLER...

  • Page 29: Performance Data

    4. PERFORMANCE DATA [a] KMD-410MAH APPROXIMATE ICE AMBIENT PRODUCTION PER 24 HR. TEMP. (ºF/ºC) lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 gal./day /day FREEZING CYCLE TIME min. HARVEST CYCLE TIME min. HEAD PRESSURE PSIG kg/cm SUCTION PRESSURE PSIG kg/cm TOTAL HEAT OF REJECTION FROM CONDENSER...

  • Page 30: [B] Kmd-410Mwh

    [b] KMD-410MWH APPROXIMATE ICE AMBIENT PRODUCTION PER 24 HR. TEMP. (ºF/ºC) lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 gal./day /day FREEZING CYCLE TIME min. HARVEST CYCLE TIME min. HEAD PRESSURE PSIG kg/cm SUCTION PRESSURE PSIG kg/cm TOTAL HEAT OF REJECTION FROM CONDENSER Note: Pressure data is recorded at 5 minutes into freezing cycle.

  • Page 31: 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 32 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 33: Diagnostic Charts

    2. DIAGNOSTIC CHARTS [a] NO ICE PRODUCTION 2. See "II. 6. [b] Bin Control Check Procedure." 5. See chart [a] [7].
  • Page 34 1. See "II. 4. Harvest Control - Thermistor." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure."...
  • Page 35 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "II. 3. [d] Control Board Check Procedure."...

  • Page 36: [B] Evaporator Is Frozen Up

    [b] EVAPORATOR IS FROZEN UP 1. Adjust or replace. See "V. 9. Adjustment of Water Regulating Valve." 1. See "II. 3. [d] Control Board Check Procedure." 1. See "V. 17. Thermistor." 1. See "II. 3. [c] Controls and Adjustments, b) Harvest Timer."...

  • Page 37: [C] Low Ice Production

    [c] LOW ICE PRODUCTION a) See chart [b] [1] and check float switch, fill and harvest water valves, control board, water pump, spray tubes, evaporator, and expansion valve. b) See chart [a] [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 38: [E] Other

    a) See chart [b] [1] & [3] and check float switch, fill and harvest water valves, control board, spray tubes, water system, refrigerant charge, and expansion valve. [e] OTHER 1. See "II. 6. [b] Bin Control Check Procedure." c) Ice Cube Guide, Water Tank, Deflector...

  • Page 39: Removal And Replacement

    2) Treatment for Refrigerant Leak [R404A] If a refrigerant leak occurs in the low side of an ice maker, air may be drawn in. Even if the low side pressure is higher than the atmospheric pressure in normal operation, a continuous refrigerant leak will eventually lower the low side pressure below the atmospheric pressure and will cause air suction.

  • Page 40: [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 41: Brazing

    2. BRAZING Note: All brazing connections inside the bin are clear coated. Sandpaper the brazing connections before unbrazing the components. Use a good abrasive cloth to remove the coating. 3. COMPRESSOR 1) Turn off the power supply. 2) Remove the panels and water tank. See "V. 14. WATER TANK."...

  • Page 42: 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 1) Turn off the power supply.

  • Page 43: 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 44: 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 45: 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 46: Water Regulating Valve - Water-Cooled Model Only

    14) Turn on the power supply. 8. WATER REGULATING VALVE – WATER-COOLED MODEL ONLY 1) Turn off the power supply. 2) Remove the panels. 3) Close the condenser water supply line shut-off valve, then open the condenser water supply line drain valve. 4) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve.

  • Page 47: 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 48: Pump Motor

    7) Replace the panels in their correct positions. 8) Turn on the power supply. 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. 4) Remove the thumbscrew securing the pump motor.

  • Page 49: 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 50: 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 51: Float Switch

    10) Install the new water tank in the reverse order of the removal procedure. 11) Refit the panels in their correct positions. 12) 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 52: Bin Control Switch

    4) Install the new float switch in the reverse order of the removal procedure. 5) Refit the panels in their correct positions. 6) Turn on the power supply. 16. BIN CONTROL SWITCH 1) Remove the water tank. See "V. 14. WATER TANK." 2) Disconnect the connector of the bin control switch lead (black).

  • Page 53: Thermistor

    8) Connect the bin control connector to the side of the control box. 9) Replace the water tank, cube guide, pump motor bracket, pump motor and float switch in their correct positions until they snap in place. Be sure to let the discharge hose pass behind the copper tube and connect it securely in position.

  • Page 54: Control Box

    8) Attach the new thermistor in position on the suction pipe and press down the thermistor holder over the thermistor. Be careful not to damage the thermistor lead. Cover the parts with the insulation and secure them with the ties. Keep the thermistor inside the thermistor holder.
  • Page 55 Control Box 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 Service Switch Fuse Fuse Holder Run Capacitor...

  • Page 56: [A] Control & Service Switch

    [a] CONTROL & SERVICE SWITCH 1) Disconnect the tab terminals and remove the nut securing the power switch. 2) Install the new switch in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label.

  • Page 57: [G] Starter

    [g] STARTER 1) Disconnect the terminals, remove the mounting screw. 2) Install the new starter in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [h] RUN CAPACITOR 1) Disconnect the terminals on the starter and remove the nut securing the run capacitor.
  • Page 58 Water Supply Tube (under Spray Tube) Spray Tube Hose Hose Band 6) The spray tube is easily cleanable by removing the black rubber caps on the ends. 7) Remove the hose band connecting the water supply tube. 8) Pull the water supply tube towards you. 9) Remove the top insulation.

  • Page 59: Cleaning And Maintenance Instructions

    1. CLEANING [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 60 7) Remove the front panel then remove the front insulation (the large insulation panel in front of the evaporator) by lifting up the panel slightly and pulling it towards you. 8) In bad or severe water conditions, clean the float switch as described below. Otherwise, continue to step 9.
  • Page 61 g. Wipe down the float switch housing, shaft and float with cleaning solution. Rinse the parts thoroughly with clean water. 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.

  • Page 62: [B] Sanitizing Procedure

    31) Remove the front panel. 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 63: [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 64 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 65 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-410mwhKmd-201aaKmd-201awa

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