Hoshizaki KMD-901MWH Service Manual
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Hoshizaki KMD-901MWH Service Manual

Modular crescent cuber
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Hoshizaki
Hoshizaki America, Inc.
"A Superior Degree
of Reliability"
www.hoshizaki.com
Modular Crescent Cuber
Models
KMD-901MAH
KMD-901MWH
KMD-901MRH
SERVICE MANUAL
™
Number: 73154
Issued: 3-28-2008

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  • Page 1 Hoshizaki Hoshizaki America, Inc. Modular Crescent Cuber Models KMD-901MAH KMD-901MWH KMD-901MRH SERVICE MANUAL “A Superior Degree of Reliability” www.hoshizaki.com ™ Number: 73154 Issued: 3-28-2008...
  • Page 2 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, write, or send an e-mail message to the HOSHIZAKI Technical Support Department for assistance. HOSHIZAKI AMERICA, INC.

  • Page 3: Table Of Contents

    CONTENTS I. Specifications ........................5 A. Icemaker ........................5 1. KMD-901MAH (air-cooled) ..................5 2. KMD-901MWH (water-cooled) ................. 6 3. KMD-901MRH (remote air-cooled) ................7 B. Condenser Unit ......................8 1. URC-9F ........................8 II. General Information ......................10 A.
  • Page 4 1. KMD-901MAH (air-cooled) ..................25 2. KMD-901MWH (water-cooled) ................26 3. KMD-901MRH (remote air-cooled) ................ 27 B. Wiring Diagrams ......................28 1. KMD-901MAH and KMD-901MWH ................ 28 2. KMD-901MRH ....................... 29 C. Performance Data ....................... 30 1. KMD-901MAH (air-cooled) ..................30 2.

  • Page 5: Specifications

    I. Specifications A. Icemaker 1. KMD-901MAH (air-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V) AMPERAGE 10.8 A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP.

  • Page 6: Kmd-901Mwh (Water-Cooled)

    2. KMD-901MWH (water-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V) AMPERAGE 7.8A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR.

  • Page 7: Kmd-901Mrh (Remote Air-Cooled)

    3. KMD-901MRH (remote air-cooled) AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with netrual for 115V) AMPERAGE 10.0A ( 5 Min. Freeze AT 104°F / WT 80°F) MINIMUM CIRCUIT AMPACITY 20 A MAXIMUM FUSE SIZE 20 A APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F) PER 24 HR.

  • Page 8: Condenser Unit

    B. Condenser Unit 1. URC-9F...
  • Page 9 AC SUPPLY VOLTAGE 115/60/1 (Connection to Icemaker) FAN MOTOR 115 V Total 1.3FLA EXTERIOR DIMENSIONS (WxDxH) 32-3/16" x 15-11/16" x 21-15/16" (817 x 398 x 558 mm) DIMENSIONS INCLUDING LEGS (WxDxH) 34-5/16" x 18-1/8" x 36-15/16" (871 x 460 x 938 mm) EXTERIOR FINISH Galvanized Steel WEIGHT...

  • Page 10: General Information

    II. General Information A. Construction 1. KMD-901MAH (air-cooled) Inlet Water Valve Water Supply Inlet Spray Tubes Hot Gas Valve Junction Box Condenser Control Box Condenser Float Switch Fan Motor Drain Valve Water Pump Expansion Valves Drier Line Valve Compressor Bin Control...

  • Page 11: Kmd-901Mwh (Water-Cooled)

    2. KMD-901MWH (water-cooled) Inlet Water Valve Water Supply Inlet Spray Tubes Hot Gas Valve Junction Box Condenser Control Box Water Regulator Float Switch Drier Drain Valve Water Pump Line Valve Expansion Valves Compressor Bin Control...

  • Page 12: Kmd-901Mrh (Remote Air-Cooled)

    3. KMD-901MRH (remote air-cooled) Water Supply Inlet Inlet Water Valve Spray Tubes Hot Gas Valve Junction Box Control Box Receiver Tank Float Switch Drier Drain Valve Water Pump Line Valve Expansion Valves Compressor Bin Control...

  • Page 13: Sequence Of Operation

    B. Sequence of Operation The steps in the sequence are as outlined below. When power is supplied, the red "POWER OK" LED and the green "BC CLOSED" LED on the control board come on (If the yellow "BC OPEN" LED is on, the unit will not start. In this case clear ice away from the bin control actuator).

  • Page 14: Normal Harvest Cycle

    5. Normal Harvest Cycle LEDs 1, 4, and 2 are on. Comp, FMR, and HGV remain energized and WV opens. PM stops. As the evaporator warms, the thermistor reaches 48°F (9°C). The control board then receives the thermistor's 3.9 kΩ signal and starts the harvest timer. When the harvest timer completes its countdown, the harvest cycle is complete.

  • Page 16: Control Board

    C. Control Board • A HOSHIZAKI exclusive solid-state control is employed in KMD-901MAH, KMD-901MWH, and KMD-901MRH Modular Crescent Cubers. • All models are pretested and factory-adjusted. CAUTION 1. Fragile, handle very carefully. 2. The control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the unit before handling or replacing the board.

  • Page 17: Control Board Layout

    1. Control Board Layout Control Products "G" Control Board "OUTPUT TEST" Button S4 Dip (used to test relays on board) "ALARM RESET" Button Switch Bin Control Switch Closed LED (green) Connector K3 Harvest Control (thermistor) Bin Control Switch Connector K4 Open LED (yellow) Mechanical Bin Control...

  • Page 18: Features

    2. Features a) Maximum Water Supply Period – 6 minutes The inlet water valve will be open during harvest for 6 minutes or the length of harvest minus 50 seconds, whichever is shorter. b) Harvest Backup Timer and Freeze Timer The harvest backup timer shuts down the icemaker if, for two cycles in a row, the harvest cycle takes more than 20 minutes to complete.

  • Page 19: F) Led Lights And Audible Alarm Safeties

    f) LED Lights and Audible Alarm Safeties The red LED indicates proper control voltage and will remain on unless a control voltage problem occurs. At startup a 5 second delay occurs while the board conducts an internal timer check. A beep occurs when the control switch is moved to the "ICE" position. The green LEDs 1 through 4 energize and sequence from initial startup as listed in the table below.

  • Page 20: Controls And Adjustments

    However, a setting longer than the factory setting may be advised in cases where the flush provided at harvest needs to be prolonged for extra cleaning. Before changing this setting, call the HOSHIZAKI Technical Support Department at 1-800-233-1940 for recommendations. Keep in mind that setting the harvest timer to a longer setting will decrease 24 hour production.

  • Page 21: C) Pump-Out Timer (S4 Dip Switch 3 & 4)

    c) Pump-Out Timer (S4 dip switch 3 & 4) CAUTION Leave in the factory default position; otherwise, the drain valve and water valve will not operate at pump out. When a freeze cycle is completed, the pump motor stops, and the icemaker resumes operation in 2 seconds.

  • Page 22: E) S4 Dip Switch 7 & 8

    e) S4 Dip Switch 7 & 8 Factory set for optimum performance. Do not adjust. f) Freeze Timer (S4 dip switch 9 & 10) CAUTION Adjust to proper specification, or the unit may not operate correctly. The freeze timer setting determines the maximum allowed freeze time to prevent possible freeze-up issues.

  • Page 23: Control Board Replacement

    3) The "OUTPUT TEST" button provides a relay sequence test. Make sure the control switch is in the "ICE" position, then press the "OUTPUT TEST" button. The correct lighting sequence should be 1, 4, 3, 2. Some components (e.g., the compressor) will cycle during the test.

  • Page 24: Bin Control

    E. Bin Control This machine uses a lever-actuated proximity switch (mechanical bin control) to control the ice level in the storage bin. No adjustment is required. 1. Explanation of Operation The bin control is connected to the red K4 connector on the control board. When the bin control is calling for ice (proximity switch closed;...

  • Page 25: Technical Information

    III. Technical Information A. Water Circuit and Refrigeration Circuit 1. KMD-901MAH (air-cooled)

  • Page 26: Kmd-901Mwh (Water-Cooled)

    2. KMD-901MWH (water-cooled)

  • Page 27: Kmd-901Mrh (Remote Air-Cooled)

    3. KMD-901MRH (remote air-cooled)

  • Page 28: Wiring Diagrams

    B. Wiring Diagrams 1. KMD-901MAH and KMD-901MWH...

  • Page 29: Kmd-901Mrh

    2. KMD-901MRH...

  • Page 30: Performance Data

    C. Performance Data 1. KMD-901MAH (air-cooled) 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 1810 1848 1876 CONSUMPTION 80/27 1839 1898 1913 90/32 1848 1940 1961 watts...

  • Page 31: Kmd-901Mwh (Water-Cooled)

    2. KMD-901MWH (water-cooled) 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 1480 1492 1507 CONSUMPTION 80/27 1489 1507 1522 90/32 1492 1520 1536 watts...

  • Page 32: Kmd-901Mrh (Remote Air-Cooled)

    3. KMD-901MRH (remote air-cooled) 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 1600 1632 1670 CONSUMPTION 80/27 1709 1625 1675 90/32 1632 1710 1746 watts 100/38 1638...

  • Page 33: Service Diagnosis

    IV. Service Diagnosis A. 10-Minute Diagnostic Procedure The 10 minute check out procedure is basically a sequence check which can be used at unit start-up or for system diagnosis. Using this check out procedure will allow you to diagnose electrical system and component failures in approximately 10 minutes under normal operating conditions of 70°F (21°C) or warmer air and 50°F (10°C) or warmer water temperatures.

  • Page 34: Diagnostic Charts

    5) Freeze Cycle – LED 1 is on. Compressor (and fan motor on a remote air-cooled unit) remains energized, pump motor, (line valve if applicable), and fan motor (self-contained air-cooled unit) energize. The inlet water valve and hot gas valve de-energize. The unit is held in freeze by a 5 minute short cycle protection timer.
  • Page 35 Problem Possible Cause Remedy [1] The icemaker will not d) Control Switch 1. "OFF" or "WASH" 1. Move to "ICE" position. start. (continued) position. 2. Bad contacts. 2. Check for continuity and replace. e) Bin Control 1. Tripped with bin filled 1.
  • Page 36 Problem Possible Cause Remedy [1] The icemaker will not l) Inlet Water Valve 2. Coil winding opened. 2. Replace. start. (continued) (continued) 3. Wiring to water valve. 3. Check for loose connection or open, and replace. m)Control Board 1. Defective or in alarm. 1. See "II.C.4. Control Board Check Procedure."...
  • Page 37 Problem Possible Cause Remedy [5] Water pump will not a) Pump Motor 6. Mechanical seal worn 6. Check and replace. start. (continued) (continued) out. b) Control Board 1. Defective. 1. See "II.C.4. Control Board Check Procedure." c) Control Switch 1. Bad contacts. 1.

  • Page 38: Evaporator Is Frozen Up

    2. Evaporator is Frozen Up Problem Possible Cause Remedy [1]Freeze cycle time is a) Float Switch 1. Leads short-circuit or 1. Check and replace. too long. defective switch. 2. Float does not move 2. Clean or replace. freely. b) Inlet Water Valve 1.

  • Page 39: Low Ice Production

    Problem Possible Cause Remedy [3]Other. (continued) c) Refrigerant 1. Low charge. 1. Check for leaks and recharge. d) Expansion Valve 1. Bulb out of position or 1. Place in position. loose attachment. 2. Defective. 2. Replace. e) Hot Gas Valve 1.

  • Page 40: Other

    5. Other Problem Possible Cause Remedy [1] Icemaker will not stop a) Bin Control 1. Defective. 1. See "II.E.2. Bin Control when bin is filled with Check Procedure." ice. [2] Abnormal noise. a) Pump Motor 1. Bearings worn out. 1. Replace. b) Fan Motor (except 1.

  • Page 41: Removal And Replacement Of Components

    V. Removal and Replacement of Components IMPORTANT 1. Ensure all components, fasteners, and thumbscrews are securely in place after the equipment is serviced. 2. 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 42: Evacuation And Recharge (R-404A)

    Remember to loosen the connection and purge the air from the hose. For air- cooled and water-cooled models, see the nameplate for the required refrigerant charge. For remote air-cooled models, see the rating label inside the icemaker. Hoshizaki recommends only virgin refrigerant or reclaimed refrigerant which meets ARI Standard No.

  • Page 43: Removal And Replacement Of Compressor

    B. 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 44: Removal And Replacement Of Expansion Valve

    C. Removal and Replacement of Expansion Valve IMPORTANT Sometimes moisture in the refrigeration 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 45: Removal And Replacement Of Hot Gas Valve Or Line Valve

    D. Removal and Replacement of Hot Gas Valve or Line Valve IMPORTANT 1. Always use a copper tube of the same diameter and length when replacing the hot gas lines; otherwise the performance may be reduced. 2. Always install a new drier every time the sealed refrigeration system is opened.

  • Page 46: Removal And Replacement Of Evaporator

    E. Removal and Replacement of Evaporator IMPORTANT Always install a new drier every time the sealed refrigeration system is opened. Do not replace the drier until after all other repairs or replacement have been made. 1) Turn off the power supply. 2) Remove the panels and the front and top insulation.

  • Page 47: Adjustment Of Water Regulating Valve - Water-Cooled Model Only

    4) Attach a compressed air or carbon dioxide supply to the condenser water supply line drain valve. 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.

  • Page 48: Removal And Replacement Of Headmaster (Condensing Pressure Regulator - C

    H. Removal and Replacement of Headmaster (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.

  • Page 49: Removal And Replacement Of Thermistor

    I. Removal and Replacement of Thermistor IMPORTANT 1. Fragile, handle very carefully. 2. Always use the recommended sealant (high thermal conductive type), Model KE4560RTV manufactured by SHINETSU SILICONE, Part Code 60Y000-11, or Part Code 4A0683-01 or equivalent. 3. Always use the recommended foam insulation (non-absorbent type) or equivalent.

  • Page 50: Removal And Replacement Of Fan Motor

    J. 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).

  • Page 51: Removal And Replacement Of Pump Motor

    L. Removal and Replacement of Pump Motor 1) Turn off the power supply. 2) Remove the front panel. Remove the insulation panel. Remove cube guide B, then remove cube guide A. Remove the overflow cap, overflow pipe, and water shield. See Fig.

  • Page 52: Removal And Replacement Of Bin Control

    M. Removal and Replacement of Bin Control 1) Turn off the power supply. 2) Remove the front panel and top panel. 3) Remove the control box cover. 4) Disconnect the bin control connector from the bin control wire harness. The wire harness is connected to the K4 connector on the board.

  • Page 53: Cleaning And Maintenance

    Ensure all components, fasteners, and thumbscrews are securely in place after any cleaning or maintenance is done to the equipment. A. Cleaning and Sanitizing Instructions HOSHIZAKI recommends cleaning this icemaker at least once a year. More frequent cleaning, however, may be required in some existing water conditions. WARNING 1.

  • Page 54: Cleaning Procedure

    1. Cleaning Procedure 1) Dilute 13.5 fl. oz. (400 ml) of Hoshizaki "Scale Away" with 2.5 gal. (9.5 l) of warm 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 back on after 3 minutes.

  • Page 55: Sanitizing Procedure - Following Cleaning Procedure

    9) Fully open the cleaning valve on the left side wall of the machine compartment. 10) Move the control switch on the control box to the "WASH" position. Replace the insulation panel and the front panel in their correct positions. 11) Turn on the power supply to start the washing process.

  • Page 56: Maintenance

    3) Pour the sanitizing solution into the water tank. 4) Replace the insulation panel and the front panel in their correct positions. Note: Make sure that the control switch is in the "WASH" position and the cleaning valve is open. 5) Turn on the power supply to start the sanitizing process.

  • Page 57: Preparing The Icemaker For Long Storage

    3. Air Filters (air-cooled model only) Plastic mesh air filters remove dirt and dust from the air, and keep the condenser from getting clogged. As the filters get clogged, the icemaker’s performance will be reduced. Check the filters at least twice a month. When clogged, use warm water and a neutral cleaner to wash the filters.
  • Page 58 6) Blow the icemaker water supply line out using the compressed air or carbon dioxide supply. 7) Close the icemaker water supply line drain valve. 3. Drain the water tank: 1) Turn off the power supply. 2) Move the control switch to the "OFF" position. 3) Remove the insulation panel.

This manual is also suitable for:

Kmd-901mahKmd-901mrh

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