Hoshizaki KM-2000SWH3 Service Manual
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Hoshizaki KM-2000SWH3 Service Manual

Hoshizaki KM-2000SWH3 Service Manual

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STACKABLE CRESCENT CUBER
MODEL
HOSHIZAKI
KM-2000SWF3
KM-2000SRF3
KM-2000SWH3
KM-2000SRH3
SERVICE MANUAL
NO:
73081
ISSUED:
OCT. 9, 1998
REVISED:
DEC. 16, 2003

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  • Page 1 73081 ISSUED: OCT. 9, 1998 REVISED: DEC. 16, 2003 HOSHIZAKI STACKABLE CRESCENT CUBER KM-2000SWF3 MODEL KM-2000SRF3 KM-2000SWH3 KM-2000SRH3 SERVICE MANUAL...
  • Page 2 No service or maintenance should be undertaken until the technician has thoroughly read this Service Manual. 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 or write to the HOSHIZAKI Technical Support Department for assistance.

  • Page 3: Table Of Contents

    CONTENTS PAGE I. SPECIFICATIONS ....................5 1. KM-2000SWF3, KM-2000SWH3 (Water-cooled, 3 phase) ........5 2. KM-2000SRF3, KM-2000SRH3 (Remote air-cooled, 3 phase) ......6 3. CONDENSING UNIT, URC-20F ................. 7 II. GENERAL INFORMATION ..................9 1. CONSTRUCTION ....................9 [a] KM-2000SWF3, KM-2000SWH3 ..............
  • Page 4 2. BRAZING ......................37 3. REMOVAL AND REPLACEMENT OF COMPRESSOR........38 4. REMOVAL AND REPLACEMENT OF DRIER ............ 39 5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE ......40 6. REMOVAL AND REPLACEMENT OF HOT GAS VALVE ........AND LINE VALVE ....................41 7.

  • Page 5: Specifications

    I. SPECIFICATIONS 1. KM-2000SWF3, KM-2000SWH3 (Water-cooled) We reserve the right to make changes in specifications and design without prior notice.

  • Page 6: Km-2000Srf3, Km-2000Srh3 (Remote Air-Cooled, 3 Phase)

    2. KM-2000SRF3, KM-2000SRH3 (Remote air-cooled) We reserve the right to make changes in specifications and design without prior notice.

  • Page 7: Condensing Unit, Urc-20F

    3. CONDENSING UNIT URC-20F...
  • Page 8 SPECIFICATIONS MODEL: URC-20F EXTERIOR Galvanized Steel 46 - 3/8" x 15 - 11/16" x 25 - 15/16" DIMENSIONS (W x D x H) (1178 x 398 x 659 mm) REFRIGERANT CHARGE R404A 7 lbs.11 oz. (3500 g) URC-20F Net 104 lbs. (47 kg) Shipping 150 lbs.

  • Page 9: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION [a] KM-2000SWF3, KM-2000SWH3 Evaporator Spray Tube Water Valve Expansion Valve Water Supply Inlet Check Valve Hot Gas Valve Junction Box Control Box Water-cooled Condenser Line Valve Water Regulator Water Pump Float Switch Transformer Box Cleaning Valve...

  • Page 10: [B] Km-2000Srf3, Km-2000Srh3

    [b] KM-2000SRF3, KM-2000SRH3 Evaporator Spray Tube Water Valve Expansion Valve Water Supply Inlet Check Valve Hot Gas Valve Junction Box Control Box Receiver Tank Water Pump Line Valve Float Switch Transformer Box Cleaning Valve Drier Compressor Control Switch Bin Control Thermostat...

  • Page 11: Controller Board

    2. CONTROLLER BOARD [a] SOLID-STATE CONTROL 1) A HOSHIZAKI exclusive solid-state control is employed in KM-2000SWF3, KM-2000SRF3, KM-2000SWH3, and KM-2000SRH3 Stackable Crescent Cubers. 2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and high quality control system.
  • Page 12 2) Defrost Timer The defrost cycle starts when the Float Switch opens and completes the freeze cycle. But the Defrost Timer does not start counting until the Thermistor senses 48°F at the Evapora- tor outlet. The period from the end of the freeze cycle up to the point of the Thermistor's sensing varies depending on the ambient and water temperatures.
  • Page 13 problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A short beep occurs when the power switch is turned ON or OFF. The green LED’s 1-4 represent the corresponding relays and energize and sequence 5 seconds from initial startup as follows: Sequence Step LED’s on Length:...
  • Page 14 to the K1 connector. If there is a white wire, place the switch in the C position. If this switch is placed in the wrong position either the compressor contactor will remain ener- gized with the control switch OFF or the unit will not start. The dip switches should be adjusted per the adjustment chart published in the Tech Specs book.
  • Page 15 (Control Products HOS-001A Board)

  • Page 16: [C] Sequence

    [c] SEQUENCE 1st Cycle [KM-2000SWF3, KM-2000SRF3, KM-2000SWH3 and KM-2000SRH3] 3. Thermistor reads 48°F. 1. Unit energized and Control Switch to “ICE” Defrost Timer starts counting. position. Water supply cycle starts. 2. After 1 minute. Defrost cycle starts. IMPORTANT Water Valve opening is limited to 6 minutes.
  • Page 17 2nd Cycle and after with pump drain [KM-2000SWF3, KM-2000SRF3, KM-2000SWH3 and KM-2000SRH3] IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open. 2. Drain timer stops counting. 1. Float Switch opens and signals to complete Pump drain is completed freeze cycle.
  • Page 18 2nd Cycle and after with no pump drain [KM-2000SWF3, KM-2000SRF3, KM-2000SWH3 and KM-2000SRH3] IMPORTANT Freeze cycle time is limited to 60 minutes even if Float Switch does not open. 2. Thermistor reads 48° F. 1. Float Switch opens and signals to complete Defrost Timer starts counting.

  • Page 19: [D] Controls And Adjustments

    [d] CONTROLS AND ADJUSTMENTS The Dip Switch is factory-adjusted to the following positions: DIP SWITCH NO. KM-2000S_F3, OFF OFF OFF OFF KM-2000S_H3 Switch Nos. 1 and 2: Used for adjustment of the Defrost Timer. The Defrost Timer starts counting when the Thermistor reads a certain temperature at the Evaporator outlet.
  • Page 20 1) Defrost Control A thermistor (Semiconductor) is used for a defrost control sensor. The resistance varies depending on the Suction Line temperatures. The Thermistor detects the temperature of the Evaporator outlet to start the Defrost 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 21 3) Drain Timer The Drain Timer is factory-adjusted, and no adjustment is required. SETTING TIME Dip Switch Dip Switch No. 3 No. 4 10 seconds 150 seconds 10 seconds 180 seconds 10 seconds 120 seconds 20 seconds 180 seconds T1: Time to drain the Water Tank T2: Time to restrain defrost completion 4) Drain Counter CAUTION...

  • Page 22: [E] Checking The Controller Board

    5) Freeze Timer CAUTION Adjust to proper specification, or the unit may not operate correctly. Two new dip switches numbered 9 and 10 have been added to the improved “E” board to better prevent possible freeze ups. These settings come factory set to the default setting of 60 min.
  • Page 23 After the 1 minute ± 5 second water supply cycle and the 2 minute ± 10 second defrost cycle, the unit should start the freeze cycle. (ii) After the above step (i), disconnect the Float Switch leads from the Controller Board within the first 5 minutes of the freeze cycle.

  • Page 24: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT [a] KM-2000SWF3, KM-2000SWH3...

  • Page 25: [B] Km-2000Srf3, Km-2000Srh3

    [b] KM-2000SRF3, KM-2000SRH3...

  • Page 26: Wiring Diagrams

    2. WIRING DIAGRAMS [a] KM-2000SWF3 KM-2000SWH3 [b] KM-2000SRF3 KM-2000SRH3 KM-2000SWF3, KM-2000SWH3 KM-2000SRF3, KM-2000SRH3 Pressure Switch Pressure Switch +21.3 +21.3 Cut-out PSIG Cut-out PSIG Cut-in 284 ± 21.3 PSIG Cut-in 327 ± 21.3 PSIG...

  • Page 27: Timing Chart

    3. TIMING CHART *1 The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”...
  • Page 28 The Pump Motor waits for 2 seconds before starting a drain cycle. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.” The icemaker does not complete a defrost cycle in the first 2 or 3 minutes. See “II. 2. [d] CONTROLS AND ADJUSTMENTS.”...

  • Page 29: Performance Data

    4. PERFORMANCE DATA [a] KM-2000SWF3, KM-2000SWH3 Note: Pressure data is recorded first 5 minutes in freezing cycle. The data not in bold should be used for reference. We reserve the right to make changes in specifications and design without prior notice.

  • Page 30: [B] Km-2000Srf3, Km-2000Srh3

    [b] KM-2000SRF3, KM-2000SRH3 Note: Pressure data is recorded first 5 minutes in freezing cycle. The data not in bold should be used for reference. We reserve the right to make changes in specifications and design without prior notice.

  • Page 31: Service Diagnosis

    IV. SERVICE DIAGNOSIS 1. NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker a) Power Supply 1. “OFF” position. 1. Move to “ON” position. will not start 2. Loose connections. 2. Tighten. 3. Bad contacts. 3. Check for continuity and replace.
  • Page 32 PROBLEM POSSIBLE CAUSE REMEDY l) Controller Board 1. Defective. 1. See “II.2[e] CHECKING CONTROLLER BOARD.” m) Interlock Switch 1. “OFF” position. 1. Move to “ON” position. (Cleaning Valve) 2. Bad contacts. 2. Check for continuity and replace. [2] Water a) Float switch 1.
  • Page 33 PROBLEM POSSIBLE CAUSE REMEDY [5] No water a) Water Supply Line 1. Water pressure too low and 1. Check and get comes from water level in Water Tank recommended pressure. Spray Tubes. too low. Water Pump b) Water Solenoid 1. Dirty mesh filter or orifice 1.

  • Page 34: Evaporator Is Frozen Up

    2. EVAPORATOR IS FROZEN UP PROBLEM POSSIBLE CAUSE REMEDY [1] Freeze cycle a) Float Switch 1. Leads short-circuit or 1. Check and replace. time is too defective switch. long. 2. Float does not move freely. 2. Clean or replace. b) Water Solenoid 1.

  • Page 35: Low Ice Production

    3. LOW ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] Freeze cycle a) See chart 1 - [3], and check dirty Air Filter or Condenser, ambient or water time is long. temperature, water pressure, Water Regulator or refrigerant charge. b) See chart 2 - [1], and check Float Switch, Water Solenoid Valve or Controller Board.

  • Page 36: Removal And Replacement Of Components

    V. REMOVAL AND REPLACEMENT OF COMPONENTS IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after the equipment is serviced. IMPORTANT 1. 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 37: Brazing

    Remember to loosen the connection, and purge the air from the Hose. For water-cooled models, see the Nameplate for the required refrigerant charge. For remote air-cooled models, see the Charge Label in the machine compartment. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No.

  • Page 38: Removal And Replacement Of Compressor

    3. 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 39: Removal And Replacement Of Drier

    15) Evacuate the system, and charge it with refrigerant. See the Nameplate for the required refrigerant charge. 16) Connect the Terminals, and replace the Terminal Cover in its correct position. 17) Replace the panels in their correct positions. 18) Turn on the power supply. 4.

  • Page 40: Removal And Replacement Of Expansion Valve

    5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE IMPORTANT Sometimes moisture in the refrigerant 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 41: Removal And Replacement Of Hot Gas Valve And Line Valve

    6. REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND LINE VALVE CAUTION Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced. 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 42: Removal And Replacement Of Evaporator

    11) Connect the new Solenoid leads. 12) Attach the Solenoid to the valve body, and secure it with a screw. 13) Replace the panels in their correct positions. 14) Turn on the power supply. 7. REMOVAL AND REPLACEMENT OF EVAPORATOR IMPORTANT Always install a new Drier every time the sealed refrigeration system is opened.

  • Page 43: Removal And Replacement Of Water-Regulating Valve

    8. REMOVAL AND REPLACEMENT OF 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 44: Adjustment Of Water Regulating Valve - Water-Cooled Model Only

    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. Adjust the Water Regulator, if necessary, using the following procedures. 1) Attach a pressure gauge to the high-side line of the system. Or prepare a thermometer to check for the condenser drain temperature.

  • Page 45: Removal And Replacement Of Condensing Pressure

    10. REMOVAL AND REPLACEMENT OF 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. 1) Turn off the power supply.

  • Page 46: Removal And Replacement Of Thermistor

    11. REMOVAL AND REPLACEMENT OF THERMISTOR CAUTION 1. Fragile, handle very carefully. 2. Always use a recommended sealant (High Thermal Conductive Type), Model KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y000-11, or Part Code 4A0683-01 equivalent. 3. Always use a recommended foam insulation (Non-absorbent Type) or equivalent. 1) Turn off the power supply.

  • Page 47: Removal And Replacement Of Fan Motor

    12. 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). 4) Remove the closed end connectors from the Fan Motor leads.

  • Page 48: Removal And Replacement Of Water Valve

    13. REMOVAL AND REPLACEMENT OF WATER VALVE 1) Turn off the power supply. 2) Close the Water Supply Line Shut-off Valve. 3) Remove the Front Panel. 4) Remove the Valve Outlet Tubing by releasing the Clamp. 5) Remove the Bracket from the unit. 6) Remove the Fitting Nut and Water Valve.

  • Page 49: Removal And Replacement Of Spray Tubes

    7) Remove the closed end connectors from the Pump Motor leads. 8) Remove the two screws and the Pump Motor Bracket. 9) Remove the Pump Housing, and check the Impeller. 10) If the Impeller is defective, install a new Impeller. 11) Install the new motor or new parts, and replace the removed parts in the reverse order of which they were removed.

  • Page 50: Cleaning And Maintenance Instructions

    VI. CLEANING AND MAINTENANCE INSTRUCTIONS 1. PREPARING THE ICEMAKER FOR LONG STORAGE IMPORTANT Ensure all components, fasteners and thumbscrews are securely in place after any maintenance or cleaning is done to the equipment. WARNING When shutting off the icemaker for an extended time, drain out all water from the water tank and remove the ice from the Storage Bin.
  • Page 51 [2] Remove the water from the potable water supply line: 1) Remove the Front Panel. (Except water-cooled model) 2) Move the Control Switch, on the Control Box, to the “OFF” position. 3) Wait 3 minutes. 4) Close the Potable Water Supply Line Shut-off Valve and open the Potable Water Supply Line Drain Valve.

  • Page 52: Cleaning Procedure

    WARNING 1. HOSHIZAKI recommends cleaning this unit at least once a year. More frequent cleaning, however, may be required in some existing water conditions. 2. To prevent injury to individuals and damage to the icemaker, do not use ammonia type cleaners.

  • Page 53: [A] Cleaning Procedure

    [a] CLEANING PROCEDURE 1) Dilute 38 fl. oz. of the recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 7 gal. of 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 on after 3 minutes.
  • Page 54 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” position. 23) Replace the Front Panel in its correct position.

  • Page 55: [B] Sanitizing Procedure

    [b] SANITIZING PROCEDURE - Following Cleaning Procedure 1) Dilute a 5.25% Sodium Hypochlorite solution (chlorine bleach) with water (Add 3.5 fl. oz. of sanitizer to 7 gal. of water). 2) Remove the Insulation Panel, if it is in its normal position. 3) Pour the sanitizing solution into the Water Tank.

  • Page 56: Maintenance

    3. 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 and soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. 2) Storage Bin and Scoop •...

This manual is also suitable for:

Km-2000srh3Km-2000srf3Km-2000swf3

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