Related Manuals for Hoshizaki KM-80BAJ
Summary of Contents for Hoshizaki KM-80BAJ
- Page 1 Service Manual Self-Contained Crescent Cuber Models KM-80BAJ KM-115BAJ KM-160BAJ, BWJ Number: F116-1007 hoshizakiamerica.com Issued: 04-16-2018...
- Page 2 WARNING Only quali ed service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certi ed Service Representative, visit www.hoshizaki.com. No service should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and...
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Page 3: Table Of Contents
Retain this manual for any further reference that may be necessary. CONTENTS Important Safety Information ..................4 I. Construction and Water/Refrigeration Circuit Diagram ..........6 A. Construction ......................6 1. KM-80BAJ, KM-115BAJ ...................6 2. KM-160BAJ ......................7 3. KM-160BWJ .....................8 4. Icemaking Compartment ..................9 B. Water/Refrigeration Circuit Diagram ..............10 1. - Page 4 A. Maintenance Schedule ..................52 VI. Preparing the Appliance for Periods of Non-Use ............53 VII. Disposal .........................54 VIII. Technical Information ....................55 A. Speci cation Data ....................55 1. KM-80BAJ ......................55 2. KM-115BAJ ....................56 3. KM-160BAJ ....................57 4. KM-160BWJ ....................58 B. Performance Data ....................59 1.
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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, damage to the appliance, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury. - Page 6 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. •...
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Page 7: Construction And Water/Refrigeration Circuit Diagram
I. Construction and Water/Refrigeration Circuit Diagram A. Construction KM-80BAJ, KM-115BAJ Top Panel Separator Spray Tube Evaporator Door Water Supply Tube Front Panel Tank Louver Control Box Control Switch Condenser Fan Motor Front View Hot Gas Valve Air Filter Thermistor Cleaning... -
Page 8: Km-160Baj
2. KM-160BAJ Top Panel Separator Spray Tube Evaporator Door Water Supply Tube Front Panel Tank Louver Control Box Control Switch Condenser Compressor Front View Hot Gas Valve Air Filter Fan Motor Thermistor Cleaning Valve Water Valve Rear Panel Pump Expansion Valve Motor Power Supply... -
Page 9: Km-160Bwj
3. KM-160BWJ Top Panel Evaporator Spray Tube Separator Water Supply Tube Door Tank Front Panel Louver Control Switch Control Box Fan Motor Front View Air Filter Condenser Compressor Cleaning Valve Thermistor Water Valve Pump Motor Expansion Valve Rear Panel Drain Valve Power Hot Gas Valve Supply... -
Page 10: Icemaking Compartment
4. Icemaking Compartment Water Valve Cleaning Valve Spray Tube Water Supply Pipe Evaporator Pump Motor Separator Cube Guide Float Switch Water Tank... -
Page 11: Water/Refrigeration Circuit Diagram
B. Water/Refrigeration Circuit Diagram KM-80BAJ, KM-115BAJ Water Inlet Capillary Tube Accumulator Water Valve Spray Tube Cleaning Valve Thermistor Pump Motor Evaporator Water Tank Float Switch Drain Valve Drain Outlet Hot Gas Drier Valve Condenser Strainer Compressor Water Circuit Refrigeration Circuit... -
Page 12: Km-160Baj
2. KM-160BAJ Water Inlet Water Valve Expansion Valve Spray Tube Thermistor Cleaning Valve Evaporator Water Tank Pump Motor Float Switch Drain Valve Drain Outlet Hot Gas Valve Compressor Strainer Pressure Switch Drier Condenser Water Circuit Refrigeration Circuit... -
Page 13: Km-160Bwj
3. KM-160BWJ Water Inlet Water Valve Expansion Valve Spray Tube Thermistor Cleaning Valve Evaporator Water Tank Float Switch Drain Valve Pump Motor Drain Outlet Hot Gas Valve Compressor Strainer Pressure Switch Drier Condenser Condenser Water Supply Water Circuit Drain Refrigeration Circuit Water Regulating Valve... -
Page 14: Sequence Of Operation And Service Diagnosis
II. Sequence of Operation and Service Diagnosis A. Sequence of Operation 1. Flow Chart... -
Page 15: Timing Chart
2. Timing Chart... -
Page 16: Details
3. Details 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, 4, and 7. a) One Minute Fill Cycle LED 8 is on. - Page 17 e) Normal Harvest Cycle LEDs 5, 6, and 8 are on. Comp continues to run, HGV remains open and WV opens. As the evaporator warms, the thermistor reaches 48°F (9°C). The control board then receives the thermistor's 3.9 k signal and starts the harvest timer. WV is open during harvest for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 &...
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Page 18: Service Diagnosis
B. Service Diagnosis WARNING • The appliance should be diagnosed and repaired only by quali ed service personnel to reduce the risk of death, electric shock, serious injury, or re. • Risk of electric shock. Control switch in "OFF" position does not de-energize all loads. - Page 19 4) Initial Harvest Cycle – The inlet water valve remains energized, contactor coil energizes to start the compressor (and fan motor on a remote condenser unit), and the hot gas valve energizes. The evaporator warms and the thermistor senses 48°F (9°C). The control board then receives the thermistor’s 3.9 k signal and turns operation of harvest over to the harvest timer.
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Page 20: Control Board Check
C. 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 CB is in alarm (beeping), press the “ALARM RESET” button on CB while CB is beeping. -
Page 21: Bin Control Check
machine to complete the freeze cycle and the following harvest cycle before shutting down the machine. When the bin control is activated, the “POWER OK” LED flashes. There is a delay before the shutdown sequence begins. The delay varies depending on the cycle the icemaker is in at the time of activation. -
Page 22: Bin Control Cleaning
2. Bin Control Cleaning Scale may build up on MBC. Scale can cause the actuator paddle and magnet to stick. In this case, MBC should be cleaned. WARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced. Make sure that none have fallen into the ice storage bin. - Page 23 Evaporator Retainer Pump Motor Hold here and pull towards you Slide Rail [both sides] Pull Stopper A [both sides] Fig. 3 Reed Switch Lead Hook Stopper B [both sides] * Fits in Stopper A Case Actuator Reed Switch Cover Fig. 4...
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Page 24: Float Switch Check And Cleaning
Pull towards you Fig. 5 8) 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. 9) Replace the removed parts in the reverse order of the removal procedure. Be sure to put the lead wire back in the retainer on the bracket. - Page 25 Cube Guide Water Tank Silicone Hose (Connect/disconnect where indicated) Over ow Pipe (Disconnect from tank Storage Bin bottom) Fig. 6 5) Check for continuity across FS lead. With the water tank empty, FS should be open. If open, continue to step 6. If closed, follow the steps in “II. E. 2. Float Switch Cleaning.“...
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Page 26: Float Switch Cleaning
FS housing, then remove the oat. Be careful not to bend the retainer rod excessively when removing it. 6) Wipe down FS housing, shaft and oat with mixture of 1 part Hoshizaki “Scale Away“ and 25 parts warm water. Rinse the parts thoroughly with clean water. - Page 27 Be careful not to bend the retainer rod excessively when removing it. 7) Wipe down FS housing, shaft, and float with mixture of 1 part Hoshizaki “Scale Away” and 25 parts warm water. Rinse the parts thoroughly with clean water.
- Page 28 Rail When tted properly, top ends of bracket and FS are ush Rounded end of slot * Secure here with screw Screw Hook A Fig. 10 10) Put the FS down into the mounting hole and hook it in position as shown. See Fig. 11.
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Page 29: Thermistor Check
F. Thermistor Check A thermistor (semiconductor) is used as a harvest control sensor and anti-slush 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. -
Page 30: Diagnostic Tables
G. Diagnostic Tables 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 31 PROBLEM POSSIBLE CAUSE REMEDY [2] Water a) Float Switch 1. Connector disconnected. 1. Reconnect. continues to be 2. Leads open or defective 2. Check and replace. supplied, and switch. the icemaker 3. Float does not move freely. 3. Clean or replace. will not start.
- Page 32 PROBLEM POSSIBLE CAUSE REMEDY [4] Water a) Inlet Water Valve 1. Diaphragm does not close. 1. Check for water leaks continues to with icemaker off. be supplied in Replace if necessary. freeze cycle. b) Control Board 1. Defective. 1. See “II. C. Control Board Check”.
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Page 33: Freeze-Up
2. Freeze-Up Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up check list. See the Hoshizaki America Technician’s Pocket Guide or contact your local distributor for a copy of the freeze-up checklist. PROBLEM POSSIBLE CAUSE REMEDY... -
Page 34: 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 regulating valve (water-cooled model), and refrigerant charge. b) See chart 2 - [1] and check float switch, inlet water valve, and control board. -
Page 35: Other
5. Other PROBLEM POSSIBLE CAUSE REMEDY [1] Icemaker will a) Bin Control Switch 1. Completely disconnected 1. Place in position. not stop when and dropped inside bin. bin is filled with 2. Detector broken. 2. Replace. ice. 3. Detector out of position. 3. -
Page 36: Controls And Adjustments
III. Controls and Adjustments * A HOSHIZAKI exclusive solid-state control is employed in crescent cubers. * All models are pretested and factory-adjusted. NOTICE • Fragile, handle very carefully. • The control board contains integrated circuits, which are susceptible to failure due to static discharge. -
Page 37: Control Board Layout
A. Control Board Layout Power Relay (FM off when LED on) Control Board Part Number P01771-02 Type HKM2006V003... -
Page 38: Led Lights And Audible Alarm Safeties
B. 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 ashes continuously when the bin is full and DV energizes for a maximum of 5 minutes to drain the water tank. -
Page 39: Settings And Adjustments
Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. 1. Default Dip Switch Settings The dip switch is factory-adjusted to the following positions: S1 Dip Switch No. KM-80BAJ OFF OFF KM-115BAJ KM-160BAJ OFF OFF KM-160BWJ S2 Dip Switch No. -
Page 40: Pump-Out Timer
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. -
Page 41: Harvest Pump Timer
Dip Switch Setting Frequency No. 5 No. 6 every cycle every 2 cycles every 5 cycles every 10 cycles 5. Harvest Pump Timer (S1 dip switch 7 & 8) The harvest pump timer allows the water valve to close and the pump motor to circulate water in the tank during the nal part of harvest. -
Page 42: Harvest Promotion Control
9. Refi ll Counter (S2 dip switch 3) Do not adjust. This must be left in the factory default position or the unit will not operate properly. The KM-80BAJ, KM-115BAJ, and KM-160BAJ/BWJ do not re ll. 10. Harvest Completion Detection Control (S2 dip switch 4) Do not adjust. -
Page 43: Overfreeze Detection Control
Do not adjust. This must be left in the factory default position or the unit will not operate properly. It is deactivated on the KM-80BAJ, KM-115BAJ, and KM-160BAJ/BWJ. When activated, the thermistor detects the temperature of the evaporator outlet to nd overfreeze in a harvest cycle and at the beginning of a freeze cycle. -
Page 44: Control Board Replacement
13. Control Board Replacement The dip switches should be adjusted to the factory default settings as outlined in this manual. D. Switches Control Switch The control switch is located at the left front of the unit. Remove the air lter to access the control switch. -
Page 45: Refrigeration Circuit And Component Service Information
IV. Refrigeration Circuit and Component Service Information WARNING • This appliance should be diagnosed and repaired only by quali ed service personnel to reduce the risk of death, electric shock, serious injury, or re. • To reduce the risk of electric shock, do not touch the control switch or plug with damp hands. -
Page 46: Refrigerant Recovery
1. Refrigerant Recovery No refrigerant access valves are provided on this appliance. Using proper refrigerant practices, utilize a temporary tap-line valve on the high side to recover the refrigerant. Store the refrigerant in an approved container. Do not discharge the refrigerant into the atmosphere. -
Page 47: Component Service Information
Remember to loosen the connection and purge the air from the hose. For the required refrigerant charge, see the nameplate. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets AHRI Standard 700 (latest edition) be used. -
Page 48: Water Tank
• Attach the new thermistor to the same location on the previous thermistor. • Smoothly ll 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. - Page 49 4) When the snaps are unhooked from the square holes, the rear part of the water tank (dotted circle in Fig. 17) is also unhooked. Hold the water tank with both hands. Pump Motor Float Switch Fig. 17 5) Tilt the right side of the water tank and pull it towards you.
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Page 50: Separator
D. Separator 1) Move the control switch to the “OFF” position, then unplug the appliance. 2) Remove the screws at the rear and take off the top panel. 3) Bend the front separator into a U-shape and remove it from the evaporator bracket shaft. -
Page 51: Door
E. Door 1) Remove the screws at the rear and take off the top panel. 2) Remove the two mounting screws and the brace. See Fig. 21. 3) Move the door so that the door shafts line up with the door channel inlets. Slide up the door to release it from the door channel. -
Page 52: Adjustment Of Water Regulating Valve (Water-Cooled Model)
F. 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. Adjust the water regulating valve, if necessary, using the following procedures. 1) Prepare a thermometer to check the condenser drain temperature. Attach a pressure gauge to the high-side line of the system. -
Page 53: Maintenance
V. Maintenance The appliance must be maintained in accordance with the instruction manual and labels provided. WARNING • Only quali ed service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the control switch or plug with damp hands. -
Page 54: Preparing The Appliance For Periods Of Non-Use
VI. Preparing the Appliance for Periods of Non-Use NOTICE • During extended periods of non-use, extended absences, or in sub-freezing temperatures, follow the instructions below to reduce the risk of costly water damage. • To prevent damage to the water pump, do not leave the control switch in the “WASH” position for extended periods of time when the water tank is empty. -
Page 55: Disposal
5) Remove all ice from the ice storage bin and clean the ice storage bin. 6) Close the door. 7) Replace the air lter in its correct position. 8) Close the icemaker water supply line drain valve. 3. On water-cooled model only, remove the water from the water-cooled condenser: 1) Make sure the control switch is in the “OFF”... -
Page 56: Technical Information
VIII. Technical Information A. Specifi cation Data 1. KM-80BAJ AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 3.5 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. -
Page 57: Km-115Baj
2. KM-115BAJ AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 5.5 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 ) *116 (53) 112 (51) 103 (47) -
Page 58: Km-160Baj
3. KM-160BAJ AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 7.1 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 ) *162 (73) 153 (69) 143 (65) -
Page 59: Km-160Bwj
4. KM-160BWJ AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 6.4 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 ) *157 (71) 154 (70) 143 (65) -
Page 60: Performance Data
B. Performance Data 1. KM-80BAJ 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 0.06 0.06 0.05 CONSUMPTION PER 24 HR. -
Page 61: Km-115Baj
2. KM-115BAJ 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 0.10 0.10 0.09 CONSUMPTION PER 24 HR. 80/27 0.10 0.09... -
Page 62: Km-160Baj
3. KM-160BAJ 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 0.17 0.15 0.14 CONSUMPTION PER 24 HR. 80/27 0.16 0.13... -
Page 63: Km-160Bwj
4. KM-160BWJ 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 0.49 0.65 1.38 CONSUMPTION PER 24 HR. 80/27 0.61 0.86... -
Page 64: Wiring Diagram
C. Wiring Diagram 1. KM-80BAJ "H"... -
Page 65: Km-115Baj
2. KM-115BAJ "H"... -
Page 66: Km-160Baj, Km-160Bwj
3. KM-160BAJ, KM-160BWJ "H" "H"...
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