Hoshizaki KM-590DJ Service Manual
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Hoshizaki KM-590DJ Service Manual

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MODULAR CRESCENT CUBER
KM-590DJ
SERVICE MANUAL
F137-1057 (073019)

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  • Page 1 MODULAR CRESCENT CUBER KM-590DJ SERVICE MANUAL F137-1057 (073019)

  • Page 2: Table Of Contents

    IMPORTANT This manual should be read carefully before the appliance is serviced. Read the warnings and guidelines contained in this manual carefully as they provide essential information for the continued safe use, service, and maintenance of the appliance. Retain this manual for any further reference that may be necessary. CONTENTS Important Safety Information ....................
  • Page 3 IV. Refrigeration Circuit and Component Service Information ..........37 A. Refrigeration Circuit Service Information ..............37 B. Component Service Information ................. 40 V. Maintenance ........................41 VI. Preparing the Icemaker for Periods of Non-Use ............42 VII. Disposal ........................43 VIII.

  • Page 4: 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 5 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. •...

  • Page 6: Construction And Water/Refrigeration Circuit Diagram

    I. Construction and Water/Refrigeration Circuit Diagram A. KM Construction KM-590DJ Spray Tubes Low-Side Service Valve Inlet Water Valve High-Side Service Valve Evaporator Assembly Thermostatic Expansion Valves Water Supply Inlet Junction Box Hot Gas Valve Check Valves (refrigeration) Cleaning Valve Condenser...

  • Page 7: Bin Control

    B. Bin Control 1. Single Bin Control Mechanical Bin Control Connection Overview Wire Harness Bin Control Cable Connector to Connector B Wire Harness Connector A (for upper unit) Wire Harness Connection Detail Control Board Red K4 Connector Wire Harness Connector B (for upper unit) Wire Harness Bin Control...

  • Page 8: Water/Refrigeration Circuit Diagram

    C. Water/Refrigeration Circuit Diagram KM-590DJ...

  • Page 9: Sequence Of Operation And Service Diagnosis

    II. Sequence of Operation and Service Diagnosis A. Sequence of Operation Flow Chart 1. Operation Flow Chart...

  • Page 10: Shutdown Flow Chart

    2. Shutdown Flow Chart...

  • Page 11: Service Diagnosis

    B. Service Diagnosis WARNING • The appliance should be diagnosed and repaired only by qualifi ed service personnel to reduce the risk of death, electric shock, serious injury, or fi re. • Risk of electric shock. Control switch in "OFF" position does not de-energize all loads Use extreme caution and exercise safe electrical practices.
  • Page 12 1. Operation Diagnosis 1) Power On: Turn on the power supply, then move the control switch to the "ICE" position. A 5-sec. delay occurs. CB red "POWER OK" LED and green "BC CLOSED" LED turn on. If yellow "BC OPEN" LED is on (indicating a full bin), check BC. Move ice away from BC actuator paddle.
  • Page 13 3a) Initial Harvest Cycle – LEDs 1, 4, and 2 are on. WV and X11 relay continue. Comp, FMR, HGV, and X10 relay energize. CB monitors the warming of the evaporator via the thermistor located on the suction line. When the thermistor reaches 9°C, CB reads 3.9 kΩ...
  • Page 14 3c) Initial Harvest Cycle Termination Diagnosis: When the thermistor reaches 9°C, CB reads 3.9 kΩ from the thermistor and turns harvest termination over to the harvest timer (S4 dip switch 1 & 2 and S5 dip switch 4). Check discharge line temperature. For a thermistor check, see "II.F.
  • Page 15 e) FM and LLV Diagnosis: If FM or LLV does not energize, check for 115VAC at CB K1 #3 (BK) to neutral (W). If 115VAC is not present, replace CB. If 115VAC is present: For FM, check capacitor, motor winding, and blade for binding. For LLV, check coil voltage and continuity.
  • Page 16 Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after 5 min. of freeze disconnect CB black K5 connector (FS connector). Check that PM stops and re-starts. Next, check that PM rotation is correct (water fl owing down the drain through CV).

  • Page 17: Control Board Check

    C. Control Board Check Before replacing CB 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 18: Bin Control Check

    D. Bin Control Check 1. Bin Control Check This appliance uses a lever-actuated proximity switch to control the ice level in the storage bin. No adjustment is required. To check BC, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel, then move the control switch to the "OFF"...

  • Page 19: Bin Control Cleaning

    4) Disconnect BC connector from CB K4 connector, then remove BC from the icemaker. 5) Remove the actuator paddle from the switch mount. See Fig. 2. 6) Wipe down BC with a mixture of 1 part of Hoshizaki "Scale Away" and 25 parts of warm water. Rinse the parts thoroughly with clean water.

  • Page 20: Float Switch Check And Cleaning

    E. Float Switch Check and Cleaning FS is used to determine that there is suffi cient water in the water tank after the 1-min. fi ll cycle and after each harvest cycle. FS is also used to determine that the appropriate volume of water has been converted into ice before switching out of the freeze cycle.

  • Page 21: Float Switch Cleaning

    Be careful not to bend the retainer rod excessively when removing it. 7) Wipe down FS housing, shaft, fl oat, 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 cleaning solution.

  • Page 22: Thermistor Check

    F. Thermistor Check To check thermistor resistance, follow the steps below. 1) Turn off the power supply. 2) Remove the front panel. Move the control switch to the "OFF" position. 3) Remove the control box cover. 4) Remove the thermistor from the refrigerant tubing. 5) Immerse the thermistor sensor portion in a glass containing ice and water for 2 or 3 min.

  • Page 23: Diagnostic Tables

    H. Diagnostic Tables 1. No Ice Production No Ice Production - Possible Cause 1. Power Supply a) Off , blown fuse, or tripped breaker. b) Not within specifi cations. 2. Main Transformer a) Voltage tap switch not set to proper voltage. b) Coil winding open or shorted.
  • Page 24 No Ice Production - Possible Cause 16 Thermostatic Expansion Valve a) Bulb loose. b) Operating erratically. 17. Liquid Line Valve a) Closed in freeze cycle. b) Open in harvest cycle. 18. Fan Motor a) Motor winding open. b) Bearing worn out or locked rotor. c) Defective capacitor.
  • Page 25 3. Freeze-Up Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up checklist. See "II.I. Freeze Up Check List," the Hoshizaki America Technician's Pocket Guide, or contact your local distributor for a copy of the freeze-up checklist.
  • Page 26 Freeze-Up - Possible Cause 8. Control Board a) Harvest timer (S4 dip switch 1 & 2) set too short. See "II.C. Control Board b) Harvest pump time (harvest assist) (S4 dip switch 7) not in factory Check" and "III.C. Settings and default position.

  • Page 27: Freeze-Up Check List

    I. Freeze-Up Check List...

  • Page 28: Controls And Adjustments

    III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KM and KMH series appliances. • All models are pretested and factory adjusted. • For a control board check procedure, see "II.C. Control Board Check." NOTICE • Fragile, handle very carefully.

  • Page 29: Control Board Layout

    A. Control Board Layout "J" Control Board • Bin Control Switch Closed LED (green) • "OUTPUT TEST" Button • S4 Dip Switch • "ALARM RESET" Button (used to test relays on control • Bin Control Switch • K3 (white) Connector Thermistor Open LED (yellow) (harvest control and...

  • Page 30: Led Lights And Audible Alarm Safeties

    B. LED Lights and Audible Alarm Safeties Beep occurs and red "POWER OK" LED turns on when control switch is moved to "ICE" position. Sequence Green LEDs 1 through 4 turn on and sequence from initial startup as listed in the table below.

  • Page 31: Settings And Adjustments

    Dip switches are factory set. Failure to maintain factory settings may adversely aff ect performance and warranty coverage. For more information, contact your Hoshizaki Service Center. 1. Default Dip Switch Settings The dip switches are factory-adjusted to the following positions: S4 Dip Switch S4 Dip Switch No.

  • Page 32: Harvest Time (S4 Dip Switch 1 & 2)

    2. Harvest Time (S4 dip switch 1 & 2) The harvest timer starts counting when the thermistor reaches 9°C at the evaporator outlet and the control board reads 3.9 kΩ from the thermistor. The harvest timer is factory set, and generally no adjustment is required. However, a setting longer than the factory setting may be advised in cases where the drain provided at harvest needs to be prolonged for extra cleaning.

  • Page 33: Pump-Out Frequency Control (S4 Dip Switch 5)

    4. Pump-Out Frequency Control (S4 dip switch 5) The pump-out frequency control is factory set to drain the water tank every 10 cycles. Generally no adjustment is required. However, where water quality is bad and the icemaker needs a pump-out more often, the pump-out frequency can be adjusted. The pump-out frequency control can be set to have a pump-out occur every cycle, or every 10 cycles.

  • Page 34: Harvest Pump Time (Harvest Assist) (S4 Dip Switch 7)

    6. Harvest Pump Time (Harvest Assist) (S4 dip switch 7) NOTICE Factory set for proper operation. Do not adjust. Adjustment outside of the factory default setting may result in damage to the appliance. Depending on S4 dip switch 7 setting, the pump motor either stays off or is energized during the last seconds of the harvest cycle.

  • Page 35: Freeze Timer (S4 Dip Switch 9 & 10)

    Do not adjust. This must be left in the factory default position or the icemaker will not operate correctly. The KM-590DJ uses a single fl oat switch with no refi lls. Float switch selector used in applications where refi ll is required in the freeze cycle.

  • Page 36: Refi Ll Counter (S5 Dip Switch 2 And 3)

    10. Refi ll Counter (S5 dip switch 2 and 3) NOTICE Do not adjust. These must be left in the factory default position or the icemaker will not operate correctly. S5 Dip Switch Setting Refi ll Counter No. 2 No. 3 1 refi...

  • Page 37: Refrigeration Circuit And Component Service Information

    IV. Refrigeration Circuit and Component Service Information WARNING • This appliance should be diagnosed and repaired only by qualifi ed service personnel to reduce the risk of death, electric shock, serious injury, or fi re. • Move the control switch to the "OFF" position and turn off the power supply. Place the disconnect in the "OFF"...
  • Page 38 2. Brazing WARNING • R-404A itself is not fl ammable at atmospheric pressure and temperatures up to 80°C. • R-404A itself is not explosive or poisonous. However, when exposed to high temperatures (open fl ames), R-404A can be decomposed to form hydrofl uoric acid and carbonyl fl...
  • Page 39 5) Disconnect the gauge manifold hose from the vacuum pump and attach it to a refrigerant service cylinder. 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 ARI Standard 700 (latest edition) be used.

  • Page 40: Component Service Information

    B. Component Service Information NOTICE When replacing a component listed below, see the notes to help ensure proper operation. Component Notes Compressor 1 phase: Install a new start capacitor, run capacitor, and start relay. Thermostatic • Attach the thermostatic expansion valve bulb to the suction line in the same location as the previous bulb.

  • Page 41: Maintenance

    V. Maintenance The maintenance schedule below is a guideline. More frequent maintenance may be required depending on water quality, the appliance's environment, and local sanitation regulations WARNING • Only qualifi ed service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the control switch or service switch with damp hands •...

  • Page 42: Preparing The Icemaker For Periods Of Non-Use

    VI. Preparing the Icemaker for Periods of Non-Use NOTICE • When storing the appliance for an extended time or in sub-freezing temperatures, follow the instructions below to prevent damage. • To prevent damage to the water pump, do not operate the appliance with the control switch in the "WASH"...

  • Page 43: Disposal

    VII. Disposal The appliance contains refrigerant and must be disposed of in accordance with applicable national, state, and local codes and regulations. Refrigerant must be recovered by properly certifi ed service personnel.

  • Page 44: Technical Information

    VIII. Technical Information We reserve the right to make changes in specifi cations and design without prior notice. A. Dimensions/Specifi cations 1. KM-590DJ...

  • Page 45: Wiring Diagram

    B. Wiring Diagram 1.KM-590DJ...

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