Hoshizaki KM-2500SRH3 Service Manual
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Hoshizaki KM-2500SRH3 Service Manual

Stackable crescent cuber
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Stackable Crescent Cuber
Models
KM-2500SWH3
KM-2500SRH3
SERVICE MANUAL
™
Number: 73164
Issued: 6-10-2010

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Summary of Contents for Hoshizaki KM-2500SRH3

  • Page 1 Hoshizaki America, Inc. “A Superior Degree of Reliability” www.hoshizaki.com Stackable Crescent Cuber Models KM-2500SWH3 KM-2500SRH3 SERVICE MANUAL ™ Number: 73164 Issued: 6-10-2010...
  • 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

    Important Safety Information ... 5 I. Specifications ... 6 A. Icemaker ... 6 1. KM-2500SWH3 (water-cooled) ... 6 2. KM-2500SRH3 (remote air-cooled) ... 7 B. Condenser Unit ... 8 1. URC-23F ... 8 II. General Information ... 10 A. Construction ... 10 1.
  • Page 4 1. KM-2500SWH3 (water-cooled) ... 23 2. KM-2500SRH3 (remote air-cooled) ... 24 B. Wiring Diagrams ... 25 1. KM-2500SWH3 (water-cooled), KM-2500SRH3 (remote air-cooled) ... 25 C. Performance Data ... 26 1. KM-2500SWH3 (water-cooled) ... 26 2. KM-2500SRH3 (remote air-cooled) ... 27 IV.

  • Page 5: Important Safety Information

    Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, or damage to the unit. WARNING Indicates a hazardous situation which could result in death or serious injury. CAUTION Indicates a situation which could result in damage to the unit.

  • Page 6: Specifications

    I. Specifications A. Icemaker 1. KM-2500SWH3 (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 &...

  • Page 7: Km-2500Srh3 (Remote Air-Cooled)

    2. KM-2500SRH3 (remote 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.)

  • Page 8: Condenser Unit

    B. Condenser Unit 1. URC-23F Note: We reserve the right to make changes in specifications and design without prior notice.

  • Page 9: Specifications

    SPECIFICATIONS MODEL: URC-23F AC SUPPLY VOLTAGE FAN MOTOR EXTERIOR DIMENSIONS (WxDxH) DIMENSIONS INCLUDING LEGS (WxDxH) EXTERIOR FINISH WEIGHT CONNECTIONS - ELECTRIC - REFRIGERANT CONDENSER FAN MOTOR PROTECTION REFRIGERANT CONTROL REFRIGERANT CHARGE DESIGN PRESSURE OPERATING CONDITIONS ACCESSORIES -SUPPLIED Note: We reserve the right to make changes in specifications and design without prior notice.

  • Page 10: General Information

    II. General Information A. Construction 1. KM-2500SWH3 (water-cooled) Evaporator Assembly Check Valve (water) Water Pump Float Switch Cleaning Valve Bin Control Bulb Holder Bin Control "Z" Bracket Bin Control Extension Bracket Spray Tubes Inlet Water Valve Compressor Bin Control Thermostat Bracket Water Supply Inlet Expansion Valves Check Valves...

  • Page 11: Km-2500Srh3 (Remote Air-Cooled)

    2. KM-2500SRH3 (remote air-cooled) Evaporator Assembly Check Valve (water) Water Pump Float Switch Cleaning Valve Bin Control Bulb Holder Bin Control "Z" Bracket Bin Control Extension Bracket Spray Tubes Inlet Water Valve Expansion Valves Compressor Control Switch Bin Control Thermostat Bracket...

  • Page 12: Sequence Of Operation

    B. Sequence of Operation 1. Sequence Cycles and Shutdown The steps in the sequence are as outlined below. When power is supplied and BC is closed, CB red "POWER OK" LED comes on. There is a 5-second delay before startup. Note that the order of the LEDs from the outer edge of CB is 1, 4, 3, 2.

  • Page 13: E) Harvest Cycle

    e) Harvest Cycle Same as the initial harvest cycle. See "II.B.1.b) Initial Harvest Cycle." Note: Unit continues to cycle until BC is satisfied or power is turned off. The unit always restarts at the 1-minute fill cycle. f) Shutdown When ice contacts the thermostatic bulb (BC switch open), BC shuts down the unit within 10 seconds.

  • Page 14: Sequence Flow Chart

    2. Sequence Flow Chart...

  • Page 15: Control Board

    C. Control Board • A Hoshizaki exclusive control board is employed in KM-2500SWH3 and KM-2500SRH3 Stackable Crescent Cubers. • All models are pretested and factory-adjusted. • For a control board check procedure, see "IV.B. Control Board Check." 1. The control board is fragile; handle very carefully. 2. The control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the unit before handling or replacing the control board.

  • Page 16: Control Board Layout

    1. Control Board Layout • "ALARM RESET" Button • S4 Dip Switch • "F TIMER" Freeze Timer LED • "H TIMER" Harvest Backup Timer LED • Alarm Buzzer • "Power OK" LED (red) (lights when power is supplied to the control board) •...

  • Page 17: Features

    2. Features a) Maximum Water Supply Period – 6 minutes The inlet water valve remains energized during harvest for 6 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 18: Led Lights And Audible Alarm Safeties

    3. 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 power is turned off. The red LED indicates proper control voltage and remains on unless a control voltage problem occurs. The green LEDs 1 through 4 energize and sequence from startup as listed in the table below.

  • Page 19: Controls And Adjustments

    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 harvest timer to a longer setting will decrease 24 hour production.

  • Page 20: C) Pump-Out Timer (S4 Dip Switch 3 & 4)

    c) Pump-Out Timer (S4 dip switch 3 & 4) When a pump-out is called for, the pump motor stops after the preceding freeze cycle. The pump motor energizes 2 seconds later in the reverse direction, taking water from the bottom of the tank and forcing pressure against the check valve seat allowing water to go through the check valve and down the drain.

  • Page 21: E) Bin Control Selector (S4 Dip Switch 7)

    In this case, see "IV.F.3. Low Ice Production" for possible solutions. The freeze timer is factory set, and generally no adjustment is required. Before changing this setting, contact Hoshizaki Technical Support at 1-800-233-1940 for recommendations. CAUTION S4 Dip Switch Setting Bin Control No.

  • Page 22: Bin Control

    D. Bin Control When the ambient temperature is below 45°F (7°C), the thermostatic bin control switch opens and shuts down the icemaker even if the ice storage bin is empty. When the thermostat is set in the prohibited range, the icemaker operates continuously even if the ice storage bin is filled with ice.

  • Page 23: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KM-2500SWH3 (water-cooled)

  • Page 24: Km-2500Srh3 (Remote Air-Cooled)

    2. KM-2500SRH3 (remote air-cooled)

  • Page 25: Wiring Diagrams

    B. Wiring Diagrams 1. KM-2500SWH3 (water-cooled), KM-2500SRH3 (remote air-cooled)

  • Page 26: Performance Data

    C. Performance Data 1. KM-2500SWH3 (water-cooled) APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 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 27: Km-2500Srh3 (Remote Air-Cooled)

    2. KM-2500SRH3 (remote air-cooled) APPROXIMATE ICE AMBIENT TEMP. PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION watts APPROXIMATE WATER CONSUMPTION PER 24 HR. gal./day /day FREEZING CYCLE TIME min. HARVEST CYCLE TIME min. HEAD PRESSURE PSIG kg/cm SUCTION PRESSURE...

  • Page 28: Service Diagnosis

    IV. Service Diagnosis 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Risk of electric shock. Use extreme caution and exercise safe electrical practices.
  • Page 29 4) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV remains energized. Comp, FMR, and HGV energize. WV is energized during harvest for a maximum of six minutes or the length of harvest which ever is shorter. LED 4 goes off when WV de-energizes. CB monitors the warming of the evaporator via the thermistor located on the suction line.
  • Page 30 6) Pump-Out Cycle (10/20 second pump out) – LEDs 1, 3, and 2 are on. LED 4 is on when S4 dip switch 3 & 4 are set to 3 off and 4 on. Comp and FMR remain energized, HGV energizes. WV energizes if S4 dip switch 3 off & 4 on. LLV de-energizes. PM stops for 2 seconds, then reverses for 10/20 seconds depending on pump-out timer S4 dip switch 3 &...

  • Page 31: Control Board Check

    B. Control Board Check 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. Alarm Reset: If the control board is in alarm (beeping), press the "ALARM RESET" button on the control board with power on.

  • Page 32: Bin Control Check

    C. Bin Control Check To check the thermostatic bin control, follow the steps below. When the ambient temperature is below 45°F (7°C), the bin control thermostat operates to stop the icemaker even if the ice storage bin is empty. When the thermostat is set in the prohibited range, the icemaker operates continuously even if the ice storage bin is filled with ice.
  • Page 33 8) Reconnect the black float switch connector, then replace the control box cover in its correct position. 9) Move the control switch to the "ICE" position. Replace the insulation panel and the front panel in their correct positions, then turn on the power supply. After 1 minute, the 1-minute fill cycle should end and the initial harvest cycle should begin.

  • Page 34: Thermistor Check

    7) Wipe down the float switch assembly's 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 the cleaning solution. Rinse the parts thoroughly with clean water.

  • Page 35: Diagnostic Charts

    F. Diagnostic Charts 1. No Ice Production Problem Possible Cause [1] The icemaker will not a) Power Supply start. b) Transformer (main transformer) c) Water Supply d) Bin Control Thermostat 1. Tripped with bin filled e) Fuse (Control Box) f) Control Switch g) High-Pressure Control Remedy 1.
  • Page 36 Problem Possible Cause [1] The icemaker will not h) Control Transformer start. (continued) i) Wiring to Control Board 1. Loose connections or j) Interlock Switch (Cleaning Valve) k) Thermistor l) Hot Gas Valve m)Inlet Water Valve n) Float Switch o) Control Board [2] Fill cycle will not a) Water Supply terminate.
  • Page 37 Problem Possible Cause [3] Compressor will c) Internal Overload not start or stops Protector Open (check operating. (continued) 1 through 3 to the right and d through f below) d) Starter e) Compressor f) Control Board [4] Water continues to a) Water Pressure be supplied in freeze b) Inlet Water Valve...

  • Page 38: Evaporator Is Frozen Up

    Problem Possible Cause [7] Fan motor will b) Control Board not start, or is not operating (except water-cooled model). (continued) [8] All components a) Refrigerant run, but no ice is produced. b) Compressor c) Hot Gas Valve d) Liquid Line Valve (if applicable) e) Inlet Water Valve f) Expansion Valve...
  • Page 39 Problem Possible Cause [1]Freeze cycle time is h) Expansion Valve too long. (continued) i) Control Board [2]All ice formed on a) Evaporator evaporator does not fall into bin in harvest b) Ambient and/or Water cycle. Temperature c) Water Supply Line d) Water System e) Inlet Water Valve f) Spray Tubes...

  • Page 40: Low Ice Production

    Problem Possible Cause [3]Other. a) Ice Cube Guide b) Bin Control Thermostat 1. Bulb out of position. 3. Low Ice Production Problem Possible Cause [1] Freeze cycle time is a) Inlet Water Valve long. b) Float Switch c) Evaporator d) Spray Tubes e) Water Pump f) Condenser (except water-cooled model)

  • Page 41: Abnormal Ice

    Problem Possible Cause [2] Harvest cycle time is a) Water Supply long. b) Thermistor c) Control Board d) Inlet Water Valve e) Evaporator f) Hot Gas Valve g) Expansion Valve h) Water Regulating Valve (water-cooled model) i) Liquid Line Valve (if applicable) 4.
  • Page 42 [2] Cloudy or irregular a) Evaporator cubes. b) Water System c) Spray Guide 5. Other Problem Possible Cause [1] Icemaker will not stop a) Bin Control Thermostat 1. Set too cold. when bin is filled with ice. [2] Abnormal noise. a) Pump Motor b) Fan Motor (except water-cooled model)

  • Page 43: Removal And Replacement Of Components

    V. Removal and Replacement of Components 1. This unit should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. 2. Move the control switch to the "OFF" position and turn off the power supply before servicing.

  • Page 44: Brazing

    2. Brazing 1. R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). 2. 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. 3.

  • Page 45: Removal And Replacement Of Compressor

    Remember to loosen the connection and purge the air from the hose. For water-cooled model, see the nameplate for the required refrigerant charge. For remote air-cooled model, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used.

  • Page 46: Removal And Replacement Of Expansion Valve

    10) Remove the drier, then place the new drier in position. 11) Remove the plugs from the suction, discharge, and process pipes. 12) Braze all fittings while purging with nitrogen gas flowing at a pressure of 3 to 4 PSIG. 13) Use an electronic leak detector or soap bubbles to check for leaks.

  • Page 47: Removal And Replacement Of Hot Gas Valve Or Liquid Line Valve

    9) Evacuate the system, and charge it with refrigerant. For water-cooled model, see the nameplate for the required refrigerant charge. For remote air-cooled model, see the rating label inside the icemaker. 10) Attach the expansion valve bulb to the suction line in the same location as the previous bulb.

  • Page 48: Removal And Replacement Of Evaporator

    12) Connect the new solenoid leads. 13) Attach the solenoid to the valve body and secure it with the bolt. 14) Replace the panels in their correct positions. 15) Turn on the power supply. E. Removal and Replacement of Evaporator 1.

  • Page 49: Removal And Replacement Of Water-Cooled Condenser

    F. Removal and Replacement of Water-Cooled Condenser 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant flow.

  • Page 50: Removal And Replacement Of Remote Air-Cooled Condenser

    G. Removal and Replacement of Remote Air-Cooled Condenser 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant flow.

  • Page 51: Removal And Replacement Of Water Regulating Valve (Water-Cooled Model)

    H. Removal and Replacement of Water Regulating Valve (water-cooled model) 1. Always install a new drier every time the sealed refrigeration system is opened. 2. Do not replace the drier until after all other repair or replacement has been made. Install the new drier with the arrow on the drier in the direction of the refrigerant flow.

  • Page 52: Adjustment Of Water Regulating Valve - Water-Cooled Model

    18) Check for water leaks. 19) Replace the panels in their correct positions. 20) Turn on the power supply. I. Adjustment of Water Regulating Valve - Water-Cooled Model The water regulating valve (also called "water regulator") is factory-adjusted. No adjustment is required under normal use.

  • Page 53: Removal And Replacement Of Thermistor

    8) Braze all fittings with nitrogen gas flowing at a pressure of 3 to 4 PSIG. 9) Use an electronic leak detector or soap bubbles to check for leaks. Add a trace of refrigerant to the system (if using an electronic leak detector), and then raise the pressure using nitrogen gas (140 PSIG).

  • Page 54: Removal And Replacement Of Fan Motor - Remote Air-Cooled Model

    10) Secure the insulation using the plastic cable ties. 11) Connect the white thermistor connector through the bushing of the control box to the control board WHITE K3 connector. CAUTION! Do not shorten or cut the thermistor leads. 12) Replace the control box cover and the panels in their correct positions. 13) Turn on the power supply.

  • Page 55: Removal And Replacement Of Pump Motor

    9) Close the icemaker water supply line drain valve. Open the icemaker water supply line shut-off valve. 10) Turn on the power supply. 11) Check for leaks. 12) Replace the front panel in its correct position. N. Removal and Replacement of Pump Motor 1) Turn off the power supply.

  • Page 56: Removal And Replacement Of Control Board

    O. Removal and Replacement of Control Board 1. The control board is fragile; handle very carefully. 2. The control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the unit before handling or replacing the control board.

  • Page 57: 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 1. Hoshizaki recommends cleaning this icemaker at least once a year. More frequent cleaning, however, may be required in some existing water conditions.

  • Page 58: Cleaning Procedure

    1. Cleaning Procedure 1) Dilute 38 fl. oz. (1,124 ml) of recommended cleaner Hoshizaki "Scale Away" with 7 gal. (26 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 59: Sanitizing Procedure - Following Cleaning Procedure

    18) Replace the front panel in its correct position. 19) Turn on the power supply to fill the water tank with water. 20) Turn off the power supply after 3 minutes. 21) Remove the front panel and fully open the cleaning valve. 22) Move the control switch to the "WASH"...

  • Page 60: Maintenance

    B. Maintenance 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 61 2. Drain the water tank: 1) Turn off the power supply, then remove the front panel. Move the control switch to the "OFF" position. 2) Remove the insulation panel. Remove the cap located on the front bottom part of the ice dropping hole.

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Km-2500swh3

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