Hoshizaki KMD-210AB-HC Service Manual
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Hoshizaki KMD-210AB-HC Service Manual

Modular crescent cuber
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MODULAR CRESCENT CUBER
KMD-210AB-HC
SERVICE MANUAL
F138-1074 (072020)

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Summary of Contents for Hoshizaki KMD-210AB-HC

  • Page 1 MODULAR CRESCENT CUBER KMD-210AB-HC SERVICE MANUAL F138-1074 (072020)

  • Page 2: Table Of Contents

    III. TECHNICAL INFORMATION ---------------------------------------------------------------------- 19 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT ------------------------------------------ 19 2. WIRING DIAGRAM ---------------------------------------------------------------------------------- 20 3. TIMING CHART--------------------------------------------------------------------------------------- 21 KMD-210AB-HC ------------------------------------------------------------------------------------- 21 IV. SERVICE DIAGNOSIS ------------------------------------------------------------------------------ 22 1. 10-MINUTE DIAGNOSTIC PROCEDURE ----------------------------------------------------- 22 2. DIAGNOSTIC CHARTS ----------------------------------------------------------------------------- 24...
  • Page 3 4. DRIER --------------------------------------------------------------------------------------------------- 33 5. HOT GAS VALVE ------------------------------------------------------------------------------------ 34 6. EXPANSION VALVE -------------------------------------------------------------------------------- 35 7. EVAPORATOR ---------------------------------------------------------------------------------------- 36 8. WATER REGULATING VALVE – WATER-COOLED MODEL ONLY ------------------- 37 9. ADJUSTMENT OF WATER REGULATING VALVE – WATER-COOLED MODEL ONLY ----------------------------------------------------------------------------------------- 38 10.

  • Page 4: Specifications

    I. SPECIFICATIONS 1. DIMENSIONS/SPECIFICATIONS...

  • Page 5: General Information

    II. GENERAL INFORMATION 1. CONSTRUCTION Water Supply Tube Drain Valve Water Supply Inlet Spray Guide Hot Gas Valve Spray Tube Condenser Thermistor Expansion Valve Fan Motor Compressor Cube Guide Water Tank Pump Motor Control Box Float Switch Harvest Water Valve Fill Water Valve Control Switch Service Switch...

  • Page 6: Sequence Of Operation

    (LED 9 is on when FWV is open). When the refill counter is activated, the refill will last until UF/S closes or for 60 seconds, whichever is shorter. After UF/S closes, FWV closes 3 seconds later. KMD-210AB-HC refills 1 time. After the refill, the freeze continues until LF/S opens again and terminates ice production.

  • Page 7: [E] Normal Harvest Cycle

    [e] NORMAL HARVEST CYCLE LEDs 5, 6, and 8 are on. Comp continues to run, HGV remains open and HWV opens. As the evaporator warms, the thermistor reaches 9°C. The control board then receives the thermistor’s 3.9kΩ signal and starts the harvest timer. HWV 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 &...

  • Page 9: Control Board

    3. CONTROL BOARD * A HOSHIZAKI exclusive solid-state control is employed in KMD-210AB-HC Crescent Cuber. * All models are pretested and factory-adjusted. CAUTION 1. Fragile, handle very carefully. 2. A control board contains integrated circuits, which are susceptible to failure due to static discharge.

  • Page 10: [A] Control Board Layout

    [a] CONTROL BOARD LAYOUT #4 Harvest Water Valve #5 Freeze Water Valve #1, 2, 3 Float Switch Control Board Model KMD-210AB-HC P01771-02 Part Number P01771-02 Type HKM2006V003...

  • Page 11: [B] Features

    [b] FEATURES a) Maximum Water Supply Period - 6 minutes The harvest water valve will be open during harvest for 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (adjustable by S1 dip switch 7 & 8), 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 12 f) 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 13: [C] Controls And Adjustments

    [c] CONTROLS AND ADJUSTMENTS a) Default Dip Switch Settings The dip switch is factory-adjusted to the following positions: S1 Dip Switch No. KMD-210AB-HC S2 Dip Switch * Functions of S2 dip switch nos. 2 through 6 depend on program version.
  • Page 14 c) Drain Timer (S1 dip switch 3 & 4) Once every ten freeze cycles, the drain valve opens to drain the water tank for the time determined by the drain timer. These switches also determine the time to delay completion of a harvest cycle, i.e.
  • Page 15 Do not adjust. This must be left in the factory default position or the unit will not operate properly. It is deactivated on the KMD-210AB-HC. When activated, this control promotes harvest of ice on the evaporator that is hard to remove.
  • Page 16 Do not adjust. This must be left in the factory default position or the unit will not operate properly. It is deactivated on the KMD-210AB-HC. When activated, this control determines whether ice remains on the evaporator at the end of a harvest cycle and at the beginning of a freeze cycle.

  • Page 17: [D] Control Board Check Procedure

    l) Anti-Slush Control (S2 dip switch 6) Do not adjust. This must be left in the factory default position or the unit will not operate properly. When activated (Ver. 1.1), the thermistor located on the suction line checks for a 41°F (5°C) temperature as the evaporator cools.

  • Page 18: Harvest Control - Thermistor

    4. HARVEST CONTROL – THERMISTOR A thermistor (semiconductor) is used as a harvest control sensor, anti-slush sensor, and overfreeze sensor. The resistance varies depending on the suction line temperatures. The thermistor detects the temperature of the evaporator outlet to start the harvest timer, to momentarily stop the pump motor during the freeze cycle, or to extend the harvest cycle time.

  • Page 19: Float Switch

    5. FLOAT SWITCH [a] EXPLANATION OF OPERATION The float operates 2 switches within the float switch. The lower switch (black and blue wires) is used for low water safety protection, initiating the freeze cycle refill and terminating the freeze cycle. The upper switch (black and red wires) is used to terminate the freeze cycle refill only.

  • Page 20: Bin Control

    6. 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. [a] EXPLANATION OF OPERATION The bin control is connected to the K1 connector (pins 4 & 5) on the control board. When the bin control is calling for ice (proximity switch closed;...

  • Page 21: Switches

    1) “DRAIN” KMD-210AB-HC employs the pump-out drain system. When the service switch is active and placed in the lower position, power is supplied to the pump motor and drain valve.

  • Page 22: Technical Information

    III. TECHNICAL INFORMATION 1. WATER CIRCUIT AND REFRIGERANT CIRCUIT...

  • Page 23: Wiring Diagram

    2. WIRING DIAGRAM...

  • Page 24: Timing Chart

    3. TIMING CHART Note: The refill counter is deactivated before shipping.

  • Page 25: Service Diagnosis

    IV. SERVICE DIAGNOSIS 1. 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 21°C or warmer air and 10°C or warmer water temperatures.
  • Page 26 a. Lower Float Switch 1st Activation: Refill – The refill can occur at any time during the freeze cycle (1 refill per cycle). As ice builds the water level drops in the reservoir and the lower float switch activates (opens). LED 5 comes on and the control board energizes the fill water valve.

  • Page 27: Diagnostic Charts

    2. DIAGNOSTIC CHARTS [a] NO ICE PRODUCTION PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker will a) Power Supply 1. Off, blown fuse, or 1. Turn on, replace, or not start. tripped breaker. reset. 2. Loose connection. 2. Tighten. 3. Bad contacts. 3.
  • Page 28 PROBLEM POSSIBLE CAUSE REMEDY [1] The icemaker will k) Harvest Water Valve 1. Mesh filter or orifice gets 1. Clean not start. clogged and water (continued) supply cycle does not finish. 2. Coil winding opened. 2. Replace. 3. Wiring to water valve. 3.

  • Page 29: [B] Evaporator Is Frozen Up

    PROBLEM POSSIBLE CAUSE REMEDY [6] Freeze cycle time a) Drain Valve 1. Leaking by. 1. Clean or replace. is too short. b) Float Switch 1. Dirty or erratic operation. 1. Clean or replace. c) Control Board 1. Defective. 1. See "II. 3. [d] Control Board Check Procedure."...

  • Page 30: [C] Low Ice Production

    PROBLEM POSSIBLE CAUSE REMEDY [2] All ice formed on a) Evaporator 1. Scaled up. 1. Clean. evaporator does b) Water Supply Line 1. Water pressure too low. 1. Check and get not fall into bin in recommended harvest cycle. pressure. c) Water Filter System 1.

  • Page 31: [D] Abnormal Ice

    PROBLEM POSSIBLE CAUSE REMEDY [2] Harvest cycle a) See chart [b] [2] and check evaporator, water supply line, harvest water valve, time is long. ambient and/or water temperature, line valve (if applicable), thermistor, control board, and hot gas valve. [d] ABNORMAL ICE PROBLEM POSSIBLE CAUSE REMEDY...

  • Page 32: Removal And Replacement

    V. REMOVAL AND REPLACEMENT WARNING Only trained service engineer can service the R290 refrigeration unit. 1. SERVICE FOR REFRIGERANT LINES [a] SERVICE INFORMATION 1) Allowable Compressor Opening Time and Prevention of Lubricant Mixture [R290] The compressor must not be opened more than 30 minutes in replacement or service. Do not mix lubricants of different compressors even if both are charged with the same refrigerant, except when they use the same lubricant.

  • Page 33: [B] Refrigerant Recovery

    7) Evacuation, Vacuum Pump and Refrigerant Charge [R290] Never allow the oil in the vacuum pump to flow backward. The vacuum level and vacuum pump may be the same as those for the current refrigerants. However, the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for R290.

  • Page 34: Welding Repair For R290 Refrigeration Circuit

    4) Close the low-side and high-side valves on the service manifold. 5) Disconnect the vacuum pump, and attach a refrigerant charging cylinder to accurately weigh in the liquid charge. Remember to purge any air from the charging hose. See the nameplate for the required refrigerant charge.

  • Page 35: Compressor

    WARNING Remove the R290 refrigerant from the unit in an area well-ventilated and free from open flames. Note: 1. Attach an access valve for recharging the unit charged by a lock ring. 2. All brazing connections inside the bin are clear coated. Sandpaper the brazing connections before unbrazing the components.

  • Page 36: Drier

    15) Connect the terminals and replace the terminal cover in its correct position. 16) Replace the panels and water tank in their correct positions. 17) Turn on the power supply. Note: Hoshizaki recommends that compressor starting electrics are always replaced at the same time as the compressor. 4. DRIER IMPORTANT Always install a new drier every time the sealed refrigeration system is opened.

  • Page 37: Hot Gas Valve

    5. HOT GAS VALVE CAUTION To ensure optimum performance, use a copper tube of the same diameter and length for replacement of the hot gas circuit. 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 38: Expansion Valve

    6. EXPANSION VALVE IMPORTANT The water in the refrigeration circuit may exceed the capacity of the drier and freeze in 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 39: Evaporator

    7. EVAPORATOR 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. 1) Turn off the power supply. 2) Remove the panels and the front and top insulation. 3) Remove the refrigerant from the unit and then any residual refrigerant still existing in the unit to allow welding process.

  • Page 40: Water Regulating Valve - Water-Cooled Model Only

    8. WATER REGULATING VALVE – WATER-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. 1) Turn off the power supply. 2) Remove the panels.

  • Page 41: Adjustment Of Water Regulating Valve - Water-Cooled Model Only

    19) Turn on the power supply. 9. ADJUSTMENT OF WATER REGULATING VALVE – WATER-COOLED MODEL ONLY The water regulating valve (also called "water regulator") is factory-adjusted. No adjustment is required under normal use. Adjust the water regulator, if necessary, using the following procedures.

  • Page 42: Pump Motor

    Screw Screw (Remove) (Loosen) Screw Fan Motor Fan Motor Bracket Fan Blade Cover 11. PUMP MOTOR 1) Turn off the power supply. 2) Remove the panels and front insulation. 3) Disconnect the connector of the pump motor lead. 4) Remove the thumbscrew securing the pump motor. 5) Remove the hose band connecting the discharge hose.

  • Page 43: Water Valve

    7) Remove the hose band connecting the discharge outlet and pull off the rubber hose. 8) Install the new motor in the reverse order of the removal procedure. 9) Replace the panels and front insulation in their correct positions. 10) Turn on the power supply. 12.

  • Page 44: Water Tank

    7) Remove the two mounting screws. 8) Install the new valve in the reverse order of the removal procedure. 9) Open the water supply tap. 10) Plug in the icemaker or connect the power source. 11) Check for leaks. 12) Refit the panels in their correct positions. 14.

  • Page 45: Float Switch

    9) Install the new water tank in the reverse order of the removal procedure. 10) Refit the panels in their correct positions. 11) Turn on the power supply. 15. FLOAT SWITCH 1) Remove the pump motor bracket. See "V. 14. WATER TANK." 2) Pull up the pump motor bracket from the water tank.

  • Page 46: Bin Control Switch

    4) Remove the two mounting screws, and release the Screws float switch from the tabs on the bracket. Float Switch 5) Install the new float switch in the reverse order of the removal procedure. Packing 6) Refit the panels in their correct positions. Bracket 7) Turn on the power supply.
  • Page 47 7) While pulling up the bin control lead, hook the bin control on the right side interior wall. Then push the bin control up against the bottom of the unit, and slide to the back until it snaps in place. Make sure the slotted holes at the right side of the bin control are securely placed on the collars at the bottom of the unit.

  • Page 48: Thermistor

    11) Secure the pump motor bracket with the two thumbscrews. 12) Reconnect the pump motor connector and float switch connector. 13) Replace the front insulation and front panel in their correct positions. 14) Turn on the power supply. 17. THERMISTOR 1) Turn off the power supply.

  • Page 49: Control Box

    18. CONTROL BOX 1) Turn off the power supply. 2) Remove the front panel. 3) Remove the one mounting screw, and pull the control box cover. 4) Remove the two mounting screws, and pivot the control box to the left side slightly and pull the control box towards you if needed.
  • Page 50 Screws Control Box Cover Screw Control Box Note: After replacing the components inside the control box, connect and tie the wires properly in their correct position. Especially make sure that the harness does not press the push buttons on the control board. Control Switch Control Board Service Switch...

  • Page 51: [A] Control & Service Switch

    [a] CONTROL & SERVICE SWITCH 1) Disconnect the tab terminals and remove the nut securing the power switch. 2) Install the new switch in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label.

  • Page 52: [G] Starter

    [g] STARTER 1) Disconnect the terminals, remove the mounting screw. 2) Install the new starter in the reverse order of the removal procedure. 3) To prevent miswiring, check the terminal numbers and lead wire colors with the wiring label. [h] RUN CAPACITOR 1) Disconnect the terminals on the starter and remove the nut securing the run capacitor.

  • Page 53: Spray Tube, Water Supply Tube, Spray Guide

    19. SPRAY TUBE, WATER SUPPLY TUBE, SPRAY GUIDE 1) Turn off the power supply. 2) Remove the panels and front insulation. 3) Remove the hose band connecting the hose. 4) Push the tabs on both sides of the spray tube to release the spray tube. 5) Pull the spray tube towards you.
  • Page 54 Spray Guide 11) Refit the removed parts in the reverse order of the removal procedure. Check for water leaks. IMPORTANT Fit the spray guide securely and tightly on the evaporator fin. Otherwise, cloudy or irregular ice cubes or performance reduction may be caused.

  • Page 55: Cleaning And Maintenance Instructions

    [a] CLEANING PROCEDURE 1) Dilute approximately 9.5 fl. oz. (281 ml) of recommended cleaner Hoshizaki “Scale Away” or “LIME-A-WAY” (Economics Laboratory, Inc.) with 1.8 gallon (6.8 lit.) of water. 2) Remove all ice from the evaporator and the storage bin/dispenser unit.
  • Page 56 8) In bad or severe water conditions, clean the float switch as described below. Otherwise, continue to step 9. a. Loosen the two thumbscrews securing the pump motor bracket. b. Disconnect the discharge hose. c. Disconnect the pump motor connector and the float switch connector from the side of the control box.
  • Page 57 h. Replace the float switch in its correct position. i. Replace the removed parts in the reverse order of which they were removed. 9) Pour the cleaning solution into the water tank. 10) Move the service switch to the "WASH" position. 11) Replace the front insulation and the front panel in their correct positions.

  • Page 58: [B] Sanitizing Procedure

    32) Repeat steps 18 through 31 three more times to rinse thoroughly. Note: If you do not sanitize the icemaker, go to step 14 in "SANITIZING PROCEDURE." [b] SANITIZING PROCEDURE – FOLLOWING CLEANING PROCEDURE 1) Dilute a 5.25% sodium hypochlorite solution (chlorine bleach) with water (add approximately 0.9 fl.

  • Page 59: Maintenance

    2. MAINTENANCE IMPORTANT This icemaker must be maintained individually, referring to the instruction manual and labels provided with the icemaker. [a] STAINLESS STEEL EXTERIOR To prevent corrosion, wipe the exterior occasionally with a clean, soft cloth. Use a damp cloth containing a neutral cleaner to wipe off oil or dirt build up. [b] STORAGE BIN AND SCOOP * Wash your hands before removing ice.
  • Page 60 When the icemaker is not used for two or three days, it is sufficient to only move the control switch to the “OFF” position, unless the icemaker will be at sub-freezing temperatures. 1. On water-cooled model only, first remove the water from the water-cooled condenser: 1) Turn off the power supply and remove the front panel.
  • Page 61 3. Drain the water tank: 1) Turn off the power supply and remove the front panel. 2) Move the control switch to the "SERVICE" position and move the service switch to the "DRAIN" position. 3) Replace the front panel in its correct position and turn on the power supply for 2 minutes. 4) Turn off the power supply and remove the front panel.

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