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Summary of Contents for Hoshizaki KM-230BAJ
- Page 1 Service Manual Self-Contained Crescent Cuber Models KM-230BAJ KM-300BAJ, BWJ Number: F111-1006 hoshizakiamerica.com Issued: 03-15-2018...
- Page 2 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;...
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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-230BAJ, KM-300BAJ .................6 2. KM-300BWJ .....................7 3. Icemaking Compartment ..................8 B. Water/Refrigeration Circuit Diagram ..............9 1. KM-230BAJ ......................9 2. - Page 4 A. Maintenance Schedule ..................47 VI. Preparing the Appliance for Periods of Non-Use ............48 VII. Disposal .........................49 VIII. Technical Information ....................50 A. Specification Data ....................50 1. KM-230BAJ ....................50 2. KM-300BAJ ....................51 3. KM-300BWJ ....................52 B. Performance Data ....................53 1. KM-230BAJ ....................53 2.
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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 1. KM-230BAJ, KM-300BAJ Top Panel Side Panel (L) Front Cover Rear Panel Door Air Filter Louver Side Panel (R) Power Supply Cord Top Cover Hot Gas Valve Thermistor Drain Valve Evaporator Condenser... -
Page 8: Km-300Bwj
2. KM-300BWJ Top Panel Side Panel (L) Front Cover Rear Panel Door Side Panel (R) Louver Power Supply Cord Top Cover Drain Valve Hot Gas Valve Thermistor Cleaning Valve Water Regulating Evaporator Valve Condenser Separator Water Tank Compressor Expansion Valve Water Valve Overflow Pipe Drier... -
Page 9: Icemaking Compartment
3. Icemaking Compartment Spray Tube Evaporator Water Supply Pipe Separator Cube Guide Water Tank Overflow Pipe Drain Valve Cleaning Valve Separator Water Valve Pump Motor Float Switch... -
Page 10: Water/Refrigeration Circuit Diagram
B. Water/Refrigeration Circuit Diagram 1. KM-230BAJ... -
Page 11: Km-300Baj
2. KM-300BAJ... -
Page 12: Km-300Bwj
3. KM-300BWJ... -
Page 13: Sequence Of Operation And Service Diagnosis
II. Sequence of Operation and Service Diagnosis A. Sequence of Operation 1. Flow Chart... -
Page 14: Timing Chart
2. Timing Chart... -
Page 15: 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, 7. a) One Minute Fill Cycle LED 8 is on. - Page 16 the control board setting, pump-out cycle occurs every cycle, or every 2nd, 5th, or 10th cycle (S1 dip switch 5 & 6). 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).
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Page 17: Service Diagnosis
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. - Page 18 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 kΩ signal and turns operation of harvest over to the harvest timer.
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Page 19: 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 20: 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 21 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. 1) Remove the louver. Move the control switch to the “OFF” position, then unplug the appliance.
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Page 22: Float Switch Check And Cleaning
7) 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. 8) Refit the removed parts in the reverse order of the removal procedure. -
Page 23: Float Switch Cleaning
5) Disconnect the connector of the FS lead. Remove the two mounting screws and FS. Lift off Float Switch Fig. 3 6) Wipe down shaft and float with a mixture of 1 part Hoshizaki “Scale Away” and 25 parts warm water. Rinse the parts thoroughly with clean water. -
Page 24: Thermistor Check
7) Replace FS in its correct position and secure it with the two screws. Then connect FS connector. 8) Replace the right side panel, rear panel and top panel in their correct positions. 9) Plug in the appliance, then move the control switch to the “ICE” position. Legend: CB–control board;... -
Page 25: 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 26 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 27 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 28: 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 29: 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 30: 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 31: 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 32: Control Board Layout
A. Control Board Layout 1. Control Board Layout "H" Control Board • Relay LEDs (6) (indicate which relays are energized • K7 Connector as listed below) Transformer • LED 5 (X1 Relay) Compressor (Comp) Fan Motor-Remote (FMR) • LED 6 (X2 Relay) •... -
Page 33: 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 flashes continuously when the bin is full and DV energizes for a maximum of 5 minutes to drain the water tank. -
Page 34: 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-230BAJ OFF OFF OFF OFF KM-300BAJ OFF OFF OFF OFF OFF OFF... -
Page 35: 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 36: 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 final part of harvest. -
Page 37: Pump-Out/Drain Selector
9. Refill 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-230BAJ and KM-300BAJ/BWJ do not refill. 10. Harvest Completion Detection Control (S2 dip switch 4) Do not adjust. -
Page 38: 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-230BAJ and KM-300BAJ/BWJ. When activated, the thermistor detects the temperature of the evaporator outlet to find overfreeze in a harvest cycle and at the beginning of a freeze cycle. -
Page 39: Control Board Replacement
S2 Dip Switch Setting Anti-Slush Control No. 6 Activated (Ver. 1.1) Activated (Ver. 2.0) 13. Control Board Replacement The dip switches should be adjusted to the factory default settings as outlined in this manual. D. Switches Two different control switches are used for operation. They are located on the right side of the control box which becomes accessible when the front louver is removed. - Page 40 2) CIRCULATE When the service switch is active and placed in the “CIRCULATE” position, power is supplied to the pump only. This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator. 3) WASH This machine utilizes a solenoid operated wash (bypass) valve.
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Page 41: Refrigeration Circuit And Component Service Information
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. • To reduce the risk of electric shock, do not touch the control switch or plug with damp hands. -
Page 42: Refrigerant Recovery
1. Refrigerant Recovery The icemaker is provided with a low-side refrigerant access valve. Using proper refrigerant practices, recover the refrigerant from the access valve and store it in an approved container. Do not discharge the refrigerant into the atmosphere. After recovery is complete, install a proper, permanent high-side access valve. -
Page 43: 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 44: Water Tank
• Attach the new thermistor to the same location on the previous thermistor. • 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. -
Page 45: Separator
D. Separator IMPORTANT • The front separator and rear separator are attached to the evaporator bracket with different lengths of pins. The front separator pins (10.7 mm) are longer than the rear separator pins (8.8 mm). Do not misplace the front and rear separators. •... -
Page 46: Door
4) Disconnect the silicone hose from the spray tube, and remove the spray tube from the evaporator bracket. 5) Remove the front separator by pushing the pins inserted into both sides of the evaporator bracket toward the center. See Fig. 8. Note: Be careful not to break the pins. -
Page 47: 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 48: Maintenance
V. Maintenance The appliance must be maintained in accordance with the instruction manual and labels provided. WARNING • Only qualified service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the control switch, service switch, or plug with damp hands. -
Page 49: 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 “SERVICE”... -
Page 50: Disposal
4) Close the door. 5) Replace the louver in its correct position. 6) 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” position and the appliance is unplugged from the electrical outlet. -
Page 51: Technical Information
VIII. Technical Information A. Specification Data 1. KM-230BAJ SPECIFICATION NO. ISSUED:06/02/2017 ITEM: HOSHIZAKI CRESCENT CUBER Revision 1 MODEL: KM-230BAJ AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 6.5 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 15 A... -
Page 52: Km-300Baj
2. KM-300BAJ SPECIFICATION NO. ISSUED:06/02/2017 ITEM: HOSHIZAKI CRESCENT CUBER Revision 1 MODEL: KM-300BAJ AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 8.4 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. -
Page 53: Km-300Bwj
3. KM-300BWJ SPECIFICATION NO. ISSUED:06/02/2017 ITEM: HOSHIZAKI CRESCENT CUBER Revision 1 MODEL: KM-300BWJ AC SUPPLY VOLTAGE 115/60/1 AMPERAGE 5.7 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. -
Page 54: Performance Data
B. Performance Data 1. KM-230BAJ PERFORMANCE DATA ISSUED:06/02/2017 ITEM: HOSHIZAKI CRESCENT CUBER MODEL: KM-230BAJ 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... -
Page 55: Km-300Baj
2. KM-300BAJ PERFORMANCE DATA ISSUED:06/02/2017 ITEM: HOSHIZAKI CRESCENT CUBER MODEL: KM-300BAJ 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... -
Page 56: Km-300Bwj
3. KM-300BWJ PERFORMANCE DATA ISSUED:06/02/2017 ITEM: HOSHIZAKI CRESCENT CUBER MODEL: KM-300BWJ 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 "H" CONSUMPTION 80/27 90/32 watts... -
Page 57: Wiring Diagram
C. Wiring Diagram...
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