Related Manuals for Hoshizaki KM-301BAJ
Summary of Contents for Hoshizaki KM-301BAJ
- Page 1 Service Manual Self-Contained Crescent Cuber Models KM-231BAJ KM-301BAJ, BWJ Number: 73238 hoshizakiamerica.com Issued: 7-23-2019...
- Page 2 Hoshizaki provides this manual primarily to assist qualified service technicians in the service of the appliance. 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
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 4 VI. Preparing the Appliance for Periods of Non-Use ............47 VII. Disposal ......................... 49 VIII. Technical Information ....................50 A. Specification and Performance Data Sheets ............... 50 1. KM-231BAJ ......................50 2. KM-301BAJ ......................51 3. KM-301BWJ ......................52 B. Wiring Diagram ......................53...
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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 • Do not make any alterations to the appliance. Alterations could result in electric shock, injury, fire, or damage to the appliance. • 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. Air-Cooled Models (BAJ) Top Panel Rear Panel Front Cover Door Air Filter Louver Left Side Panel Power Supply Cord Right Side Panel Top Cover Thermistor Separator Hot Gas Valve Evaporator Drain Valve Condenser Compressor Fan Motor... -
Page 8: Water-Cooled Models (Bwj)
2. Water-Cooled Models (BWJ) Top Panel Rear Left Side Panel Panel Front Cover Door Right Side Panel Louver Power Supply Cord Hot Gas Valve Separator Top Cover Drain Valve Thermistor Cleaning Valve Water Regulating Evaporator Valve Separator Condenser Water Tank Water Pump Compressor... -
Page 9: Icemaking Compartment
3. Icemaking Compartment Spray Tube Evaporator Water Supply Pipe Separator Cube Guide Water Tank Overflow Pipe Separator Drain Valve Separator Cleaning Valve Inlet Water Valve Water Pump Float Switch... -
Page 10: Water/Refrigeration Circuit Diagram
B. Water/Refrigeration Circuit Diagram 1. Air-Cooled Models (BAJ) -
Page 11: Water-Cooled Models (Bwj)
2. Water-Cooled Models (BWJ) -
Page 12: Sequence Of Operation And Service Diagnosis
II. Sequence of Operation and Service Diagnosis A. Sequence of Operation Flow Chart 1. Operation Flow Chart... -
Page 13: Shutdown Flow Chart
2. Shutdown Flow Chart... -
Page 14: 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 Use extreme caution and exercise safe electrical practices. - Page 15 b) HPS Diagnosis: Check that the condenser coil is not clogged or restricted. Let refrigeration circuit pressures equalize. If HPS does not reset and pressures are equalized, replace HPS. If pressures are not equalized, reclaim refrigerant and diagnose refrigeration circuit restriction. Check that there are no restrictions in the refrigeration circuit.
- Page 16 c) WRV Diagnosis: Confirm WRV is not leaking by. If WRV is leaking by, confirm HGV is open. Next, check for proper refrigerant pressures. If refrigerant pressures are correct, adjust or replace WRV. See "IV.C. Water Regulating Valve Adjustment (water-cooled models)." 5b) Harvest Pump Time (Harvest Assist) –...
- Page 17 Slush Control: When slush control is enabled (S2 dip switch 5 "ON"), PM de-energizes when thermistor reaches 50°F (10°C) (3.9kΩ) for 10 sec. then, energizes for 50 sec. repeatedly. When thermistor reaches 34°F (1°C) (5.9kΩ) PM de-energizes for 10 sec., energizes for 50 sec., de-energizes for 10 sec., again, then energizes the remainder of the freeze cycle.
- Page 18 g) WRV Diagnosis: WRV is factory set and generally no adjustment is required. If WRV fails to open in freeze, check for proper refrigerant pressures. See "VIII.A. Specification and Performance Data Sheets." If refrigerant pressures are correct and WRV does not open, adjust or replace as needed. See "IV.C. Water Regulating Valve Adjustment (water-cooled models)."...
- Page 19 Pump-Out Diagnosis: In the freeze cycle before pump-out (see table above), after 5 min. of freeze disconnect FS connector. Check that CB LEDs 4, 5, 6, and 7 are on, PM stops, then restarts, DV energizes, and water is flowing down the drain through DV. If not, continue to steps below.
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Page 20: 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 21: 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) Remove the louver, then move the control switch to the "OFF" position. Move the service switch to the "DRAIN"... - Page 22 2. Bin Control Cleaning Scale may build up on BC. Scale can cause the actuator paddle and magnet to stick. In this case, BC 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 dispense unit/ice storage bin.
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Page 23: Float Switch Check And Cleaning
7) Remove the actuator paddle from the switch mount. 8) Wipe down the switch mount and actuator paddle with 1 part of Hoshizaki "Scale Away" and 25 Parts warm water. Rinse the switch mount and actuator paddle thoroughly with clean water. - Page 24 See Fig. 4. 6) Wipe down FS housing, shaft, float, and retainer clip with a mixture of 1 part Hoshizaki "Scale Away" and 25 parts warm water. Rinse the parts thoroughly with clean water.
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Page 25: Thermistor Check
F. Thermistor Check To check thermistor resistance, follow the steps below. 1) Unplug the icemaker from the electrical outlet. 2) Remove the louver, then move the control switch to the "OFF" position. 3) Remove the top panel. 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 26: Switches
G. Switches Two control switches are used to control operation. These switches are referred to as the "control switch" and the "service switch" and are located on the control box. 1. Control Switch The control switch has three positions: "OFF" for power off, "ICE" for icemaking, and "SERVICE"... -
Page 27: 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) Unplugged or loose connection. b) Not within specifications. 2. Fuse (Control Box) a) Blown. 3. Control Switch a) In "OFF"... - Page 28 2. 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 29 Freeze-Up - Possible Cause Freeze Cycle 1. Evaporator a) Scaled up. b) Damaged. 2. Spray Tubes and/or Spray a) Dirty. Guides b) Out of position. 3. Refrigerant Charge a) Low. 4. Control Board a) Freeze timer (S1 dip switch 9 & 10) set incorrectly. See "II.C.
- Page 30 Low Ice Production - Possible Cause Long Freeze Cycle 1. Evaporator a) Scaled up, dirty. 2. Float Switch a) Scaled up, dirty. See "II.E. Float Switch Check b) Float sticking. and Cleaning" c) Defective switch. 3. Inlet Water Valve a) Leaking by. 4.
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Page 31: Freeze-Up Check List
I. Freeze-Up Check List... -
Page 32: Controls And Adjustments
III. Controls and Adjustments • A Hoshizaki exclusive control board is employed in KM 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 33: Control Board Layout
A. Control Board Layout 1. "H" Control Board "H" Control Board • Relay LEDs (6) (indicate which relays are energized as • K7 Connector listed below) Transformer • LED 5 (X1 Relay) Compressor (Comp) Fan Motor-Remote (FMR) • LED 6 (X2 Relay) •... -
Page 34: Led Lights And Audible Alarm Safeties
B. LED Lights and Audible Alarm Safeties Beep occurs and red CB "POWER OK" LED turns on when control switch is moved to "ICE" position. Sequence Green LEDs 4 through 8 turn on and sequence from initial startup as listed in the table below. -
Page 35: Settings And Adjustments
NOTICE Dip switches are factory set. Failure to maintain factory settings may adversely affect 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: S1 Dip Switch No. -
Page 36: Harvest Time (S1 Dip Switch 1 & 2)
2. Harvest Time (S1 dip switch 1 & 2) The harvest timer starts counting when the thermistor reaches 48°F (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 37: Pump-Out Frequency Control (S1 Dip Switch 5 & 6)
4. Pump-Out Frequency Control (S1 dip switch 5 & 6) 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 38: Freeze Timer (S1 Dip Switch 9 & 10)
In this case, see "II.H.3. Low Ice Production" for possible solutions. The freeze timer is factory set and no adjustment is required. Before changing this setting, contact Hoshizaki Technical Support at 1-800-233-1940 for recommendations. -
Page 39: Minimum Harvest Time (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-231BAJ and KM-301BAJ/BWJ do not refill. 10. Harvest Completion Detection Control (S2 dip switch 4) NOTICE Factory set for proper operation. -
Page 40: Overfreeze Detection Control (S2 Dip Switch 5)
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-231BAJ and KM-301BAJ/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 41: Slush Control (S2 Dip Switch 6)
12. Slush Control (S2 dip switch 6) NOTICE Factory set for proper operation. Do not adjust. Adjustment outside the factory default setting may result in damage to the appliance. This dip switch setting provides slush control during the freeze cycle. Disabled (OFF): When the evaporator temperature reaches 41°F (5°C) the control board reads a 4.8 kΩ... -
Page 42: 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. • Move the control switch to the "OFF" position and turn off the power supply. Place the disconnect in the "OFF"... - Page 43 2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). • 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.
- Page 44 Remember to loosen the connection and purge the air from the hose. For the required refrigerant charge, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard 700 (latest edition) be used.
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Page 45: Component Service Information
• The thermistor should be at the 12 o'clock position on the tube. • 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 46: 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 qualified 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 47: Preparing The Appliance For Periods Of Non-Use
VI. Preparing the Appliance 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 "SERVICE"... - Page 48 5) Open the water regulating valve by using a screwdriver to pry up on the spring retainer underneath the spring. While holding the valve open, blow out the condenser using the compressed air or carbon dioxide supply until water stops coming out. 6) Close the drain valve(s).
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Page 49: 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 certified service personnel. -
Page 50: Technical Information
VIII. Technical Information We reserve the right to make changes in specifications and design without prior notice. A. Specification and Performance Data Sheets Pressure data is recorded at 5 min. into freezing cycle. The data not in bold should be used for reference only. -
Page 51: Km-301Baj
2. KM-301BAJ Specification Sheet 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 ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 630 (7.10) -
Page 52: Km-301Bwj
3. KM-301BWJ Specification Sheet 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 ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F ELECTRIC W (kWH/100 lbs.) 480 (4.90) 490 (4.16) WATER gal./24HR (gal./100 lbs.) -
Page 53: Wiring Diagram
B. Wiring Diagram 1. KM-231BAJ, KM-301BAJ, KM-301BWJ...